Toro 74933, 74934 Operator's Manual

FormNo.3394-336RevA

G027429

ZMaster

®

Professional5000

SeriesRidingMower

with60inor72inTURBOFORCE
DischargeMower

ModelNo.74933—SerialNo.315000001andUp
ModelNo.74934—SerialNo.315000001andUp

®

Side

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3394-336*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002

Becauseinsomeareastherearelocal,state,orfederal
regulationsrequiringthatasparkarresterbeusedonthe
engineofthismachine,asparkarresterisavailableas
anoption.Ifyourequireasparkarrestor,contactyour
AuthorizedT oroDealer.

GenuineT orosparkarrestersareapprovedbytheUSDA
ForestryService.

Note:ItisaviolationofCaliforniaPublicResource
CodeSection4442touseoroperatetheengineonany
forest-covered,brush-covered,orgrass-coveredlandwithout
asparkarrestermufermaintainedinworkingorder,or
theengineconstricted,equipped,andmaintainedforthe
preventionofre.Otherstatesorfederalareasmayhave
similarlaws.

Theenclosed
informationregardingtheUSEnvironmentalProtection
Agency(EPA)andtheCaliforniaEmissionControl
Regulationofemissionsystems,maintenance,and
warranty.Replacementsmaybeorderedthroughthe
enginemanufacturer.

Engine Owner's Man ual

issuppliedfor

CustomerServiceandhavethemodelandserialnumbersof
yourproductready.Figure1identiesthelocationofthe
modelandserialnumbersontheproduct.Writethenumbers
inthespaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety
messagesidentiedbythesafetyalertsymbol(Figure2),
whichsignalsahazardthatmaycauseseriousinjuryordeath
ifyoudonotfollowtherecommendedprecautions.

Introduction

Thisrotary-blade,ridinglawnmowerisintendedtobeused
byresidentialhomeownersorprofessional,hiredoperators.
Itisdesignedprimarilyforcuttinggrassonwell-maintained
lawnsonresidentialorcommercialproperties.Itisnot
designedforcuttingbrushorforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperateand
maintainyourproductproperlyandtoavoidinjuryand
productdamage.Youareresponsibleforoperatingthe
productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct
andaccessoryinformation,helpndingadealer,ortoregister
yourproduct.

Wheneveryouneedservice,genuineT oroparts,oradditional
information,contactanAuthorizedServiceDealerorToro

©2015—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanicalinformation
andNoteemphasizesgeneralinformationworthyofspecial
attention.

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

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

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

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

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

ProductOverview.........................................................14

Controls...............................................................14

Specications........................................................16

Operation....................................................................17

AddingFuel...........................................................17

CheckingtheEngine-OilLevel.................................19

BreakinginaNewMachine......................................19

UsingtheRolloverProtectionSystem(ROPS)............19

ThinkSafetyFirst...................................................20

OperatingtheParkingBrake....................................21

OperatingtheMowerBlade-ControlSwitch

(PTO)...............................................................21

OperatingtheThrottle............................................22

OperatingtheIgnitionSwitch..................................22

StartingandStoppingtheEngine..............................22

TheSafety-InterlockSystem....................................23

DrivingForwardorBackward..................................24

StoppingtheMachine.............................................25

AdjustingtheHeightofCut.....................................25

AdjustingtheAnti-ScalpRollers...............................26

AdjustingtheFlowBafeCamLocks........................27

PositioningtheFlowBafe......................................27

PositioningtheSeat................................................28

UnlatchingtheSeat.................................................28

ChangingtheSeatSuspension..................................29

UsingtheDriveWheelReleaseValves.......................29

UsingtheSideDischarge.........................................29

TransportingtheMachine........................................30

LoadingtheMachine..............................................31

OperatingTips......................................................32

Maintenance.................................................................33

RecommendedMaintenanceSchedule(s)......................33

Lubrication...............................................................34

GreasingandLubrication........................................34

GreasingtheMower...............................................34

LubricatingtheCasterWheelHubs...........................35

EngineMaintenance..................................................36

ServicingtheAirCleaner.........................................36

ServicingtheEngineOil..........................................37

ServicingtheSparkPlug..........................................40

CheckingSparkArrester(ifequipped).......................41

FuelSystemMaintenance...........................................42

InspectingtheLPGSystem......................................42

ServicingtheElectronicFuelInjection

System..............................................................42

ElectricalSystemMaintenance....................................43

ServicingtheBattery...............................................43

ServicingtheFuses.................................................44

DriveSystemMaintenance.........................................45

CheckingtheSeatBelt.............................................45

CheckingtheRolloverProtectionSystem(ROPS)

Knobs...............................................................45

AdjustingtheTracking............................................45

CheckingtheTirePressure......................................46

CheckingtheWheelLugNuts..................................46

CheckingtheWheelHubSlottedNut........................46

AdjustingtheCasterPivotBearing............................46

UsingtheClutchShim............................................47

CoolingSystemMaintenance......................................49

CleaningtheEngineScreenandEngineOil

Cooler...............................................................49

CleaningtheEngineCoolingFinsand

Shrouds.............................................................49

CheckandCleantheHydraulicUnitShrouds..............49

BrakeMaintenance....................................................50

AdjustingtheParkingBrake.....................................50

BeltMaintenance......................................................51

InspectingtheBelts................................................51

ReplacingtheMowerBelt........................................51

ReplacingtheHydraulicPumpDriveBelt...................52

ControlsSystemMaintenance.....................................53

AdjustingtheControlHandlePosition......................53

AdjustingtheMotion-ControlLinkage......................53

AdjustingtheMotion-ControlDamper.....................54

AdjustingtheMotion-ControlNeutral-Lock

Pivot.................................................................55

HydraulicSystemMaintenance....................................55

ServicingtheHydraulicSystem.................................55

MowerDeckMaintenance...........................................57

LevelingtheMowerDeck........................................57

ServicingtheCuttingBlades.....................................59

RemovingtheMowerDeck.....................................61

ReplacingtheGrassDeector..................................62

Cleaning...................................................................63

CleaningtheMowerDeck........................................63

DisposingofWaste.................................................63

Storage........................................................................63

CleaningandStorage..............................................63

Troubleshooting...........................................................64

Schematics...................................................................66

3

Safety

Improperuseormaintenancebytheoperatororownercan
resultininjury.Toreducethepotentialforinjury,complywith
thesesafetyinstructionsandalwayspayattentiontothesafety
alertsymbol,whichmeansCAUTION,WARNING,or
DANGER-“personalsafetyinstruction."Failuretocomply
withtheinstructionmayresultinpersonalinjuryordeath.

Thisproductiscapableofamputatinghandsandfeetand
throwingobjects.Alwaysfollowallsafetyinstructionsto
avoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrassor,
whenequippedwithagrassbagger,forcatchingcutgrass.
Anyuseforpurposesotherthanthesecouldprovedangerous
touserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSIstandard
B71.4-2012.

Training

•ReadtheOperator'sManualandothertrainingmaterial.If

theoperator(s)ormechanic(s)cannotreadEnglishitis
theowner'sresponsibilitytoexplainthismaterialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof
theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtopeopleordamageto
property.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform
thejob.Onlyuseaccessoriesandattachmentsapproved
bythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety

glassesandhearingprotection.Longhair,looseclothing
orjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeusedand

removeallobjectssuchasrocks,toysandwirewhichcan
bethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches

andshieldsareattachedandfunctioningproperly.Donot
operateunlesstheyarefunctioningproperly.

Operation

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholesand

hiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis

engagedbeforestartingengine.Onlystartenginefrom
theoperator'sposition.

•Besureofyourfootingwhileusingthismachine,

especiallywhenbackingup.Walk,don'trun.Never
operateonwetgrass.Reducedfootingcouldcause
slipping.

•Slowdownanduseextracareonhillsides.Besureto

travelsidetosideonhillsides.Turfconditionscanaffect
themachine'sstability.Usecautionwhileoperatingnear
drop-offs.

•Slowdownandusecautionwhenmakingturnsandwhen

changingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshield,orotherguardsnot

securelyinplace.Besureallinterlocksareattached,
adjustedproperly ,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingoroverspeed

theengine.

•Stoponlevelground,disengagedrives,engageparking

brake(ifprovided),shutoffenginebeforeleavingthe
operator'spositionforanyreasonincludingemptyingthe
catchersoruncloggingthechute.

•Stopequipmentandinspectbladesafterstrikingobjects

orifanabnormalvibrationoccurs.Makenecessary
repairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesureof

aclearpath.

•Keeppetsandbystandersaway .

•Slowdownandusecautionwhenmakingturnsand

crossingroadsandsidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate
themachine;seekshelter.

4

RolloverProtectionSystem(ROPS)­UseandMaintenance

•TheROPSisanintegralandeffectivesafetydevice.Keep

afoldingROPSintheraisedandlockedpositionanduse
theseatbeltwhenoperatingthemachine.

•LowerafoldingROPStemporarilyonlywhenabsolutely

necessary.Donotweartheseatbeltwhenfoldeddown.

•Beawarethereisnorolloverprotectionwhenafolded

ROPSisinthedownposition.

•Becertainthattheseatbeltcanbereleasedquicklyin

theeventofanemergency.

•Checktheareatobemowedandneverfolddowna

foldingROPSinareaswherethereareslopes,dropoffs
orwater.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforedrivingunderany
objectsanddonotcontactthem.

•KeeptheROPSinsafeoperatingconditionby

periodicallythoroughlyinspectingfordamageand
keepingallmountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairorrevise.

•DonotremovetheROPS.

•AnyalterationstoaROPSmustbeapprovedbythe

manufacturer.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected
downandoutwardfromthemachine.

MaintenanceandStorage

•Disengagedrives,setparkingbrake,stopengineand

removekeyordisconnectsparkplugwire.W aitforall
movementtostopbeforeadjusting,cleaningorrepairing.

•Cleangrassanddebrisfromcuttingunit,drives,mufers,

andenginetohelppreventres.Cleanupoilorfuel
spillage.

•Letenginecoolbeforestoringanddonotstorenear

ame.

•Shutofffuelwhilestoringortransporting.Donotstore

fuelnearamesordrainindoors.

•Parkmachineonlevelground.Setparkingbrake.Never

allowuntrainedpersonneltoservicemachine.

•Usejackstandstosupportcomponentswhenrequired.

•Carefullyreleasepressurefromcomponentswithstored

energy.

•Disconnectthebatteryorremovesparkplugwirebefore

makinganyrepairs.Disconnectthenegativeterminalrst
andthepositivelast.Reconnectthepositiverstand
negativelast.

•Usecarewhencheckingblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only
replaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replaceallwornordamageddecals.

5

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

6

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential
danger.Replaceanydecalthatisdamagedorlost.

58-6520

1.Grease

93-7818

1.Warning—readtheOperator'sManualforinstructionson
torquingthebladebolt/nutto115-149N-m(85-110ft-lb).

106–2655

1.Warning-donottouchorapproachmovingbelts;remove
theignitionkeyandreadtheinstructionsbeforeservicing
orperformingmaintenance.

106-5517

1.Warning–donottouchthehotsurface.

99-8936

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

7

107-3069

1.Warning–thereisnorolloverprotectionwhentherollbaris
down.

2.Toavoidinjuryordeathfromarolloveraccident,keepthe
rollbarinthefullyraisedandlockedpositionandwear
theseatbelt.Lowertherollbaronlywhenabsolutely
necessary;donotwearthetheseatbeltwhentherollbaris
down.

3.ReadtheOperator'sManual;driveslowlyandcarefully.

110-2068

1.ReadtheOperator'sManual.

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin
place.

114-4466

1.Main,25A

2.PTO,10A

3.Charge,25A

4.Auxiliary,15A

110-2067

115-7445

1.Greasepulleysandspindles

2.Maintenanceinterval—50hours

8

116-3446

1.Battery4.Parkingbrake

2.Hourmeter5.Neutral

3.PTO6.Operatorpresenceswitch

116-4858

117-0346

1.Fuelleakhazard—readtheOperator'sManual;donot
attempttoremovetherollbar;donotweld,drillormodify
therollbarinanyway.

116-5988

1.Parkingbrake—engaged2.Parking
brake—disengaged

116-8726

1.ReadtheOperator’sManualforrecommendedhydrooil.

117-3848

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine

2.Thrownobjecthazard,mower-donotoperatewithoutthe
deector,dischargecoverorgrasscollectionsystemin
place.

3.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts;keepallguardsandshieldsinplace.

9

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe
distancefromthebattery.

7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries

8.Batteryacidcancause
blindnessorsevereburns.

withwaterandgetmedical
helpfast.

10.Containslead;donot
discard.

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

126-3275

1.Danger-LPGfuelisextremelyammableandvaporsare
explosive.

2.ReadtheOperator’sManual.ConsultNFPA58:Liqueed
PetroleumGasCodeforadditionalsafetyinformation.

3.Donotsmokeorreplacetank(s)aroundsourcesoffuel
ignition.

4.Donotattempttorepairormodifythetankorits
components.Contacttrainedandqualiedperson.ONLY
useLPGSystemManufacturerapprovedLPGtank(s),
ttings,andhosesthatweredesignedfortheunit.

5.Closefuelvalvewhenmowerisnotinuse,instorage,or
transporting.

6.AvoidcontactwithLPGfuel.Escapingvaporsandliquids
freezesskinoncontact.

126-2055

1.Wheellugnuttorque95ft-lb(129N-m)(4x)

2.Wheelhubnuttorque235ft-lb(319N-m)

3.ReadandunderstandtheOperator’sManualbefore
performinganymaintenance,checktorqueafterrst100
hoursthenevery500hoursthereafter.

1.ReadtheOperator’s

Manual

2.Lock

10

126-4398

3.Unlock

121–7586

127-0326

1.ReadtheOperator's
Manual.

2.Height-of-cut

1.Warning-ReadtheOperator’sManual.DoNotoperatethis
machineunlessyouaretrained.Wearhearingprotection.

2.Warning-Stayawayfrommovingparts;keepallguards
inplace.Stopengineandremovekeybeforeadjusting,
servicing,orcleaning.

3.Warning-DisengagePTO,movedriveleversouttoneutral
lockposition,engageparkingbrake,andstopenginebefore
leavingtheoperator’sposition.

3.Removethekeyfrom
theignitionandreadthe
Operator'sManualbefore
performingmaintenance
orservicingthemachine.

1.Fast

2.Variablespeedcontrol

3.Slow

4.Powertake-off(PTO)

116-8722

4.Cutting/dismembermentofhandorfoot-stayawayfrom
movingparts;keepallguardsandshieldsinplace.

5.Thrownobjecthazard-Pickupobjectsthatcouldbethrown
bymower.Donotoperatewhenpeopleandpetsareinthe
area.Keepdeectorinplace.

6.Crushing/dismembermenthazardofbystanders-donotcarry
passengers,lookforwardanddownwhenoperatingthe
machine,lookbehindanddownwhenreversing.

11

125–9383

1.Checkhydraulicoilevery50operatinghours.3.Checkthetirepressureevery50operatinghours.

2.ReadtheOperator’sManualforinformationonlubricating
themachine.

4.ReadtheOperator’sManualbeforeservicingorperforming
maintenance.

126–4553

1.Tippinghazardonslopes—donotmakesudden,tightturns;
makeslow,wideturns;donotuseonslopesnearopenwater;
donotusethismachineonslopesgreaterthan15degrees.

127–0335

2.Ramphazard—whenloadingontoatrailer ,donotusedual
ramps;onlyuseasingularrampwideenoughforthemachine
andthathasaninclinelessthan15degrees;backupthe
ramp(inreverse)anddriveforwardofftheramp.

12

126-3277

1.IMPORTANT :Onlyusereplacementtank(s)thatarefreeof
dentsordamage.Matchsizeandtyperequiredontank
specicationdecal.

2.Stopthemachineonalevelsurface,disengagePTO,and
engageparkingbrake.

3.Closethefuelvalve(s)onALLtanksbyrotatingclockwise,
continuetorunengine.

4.Whentheenginestops,removekey.

5.DisconnectLPGfuelhose(s).11.Slowlyopenfuelvalve(s)counterclockwisetoequalize

6.Unlatchcylinderbracket(s).

7.Removeemptytank(s).Checkvalveandttingsfordebrisor
damagedo-rings.

8.Installfullreplacementtank(s)byaligningcenterholeontank
collarovermountingtab.

9.Latchbracket(s)andensuretank(s)issecurelyfastenedto
mower.

10.Re-connectfuelhose(s).

pressure.Checkforleaks.

13

ProductOverview

G027420

7

6

5

4

3

2

1

8

9

10

g0131 12

1

2

3

4

5

6

25

25

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ENG

IN

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Figure5

Figure4

1.Height-of-cutdecklift
pedal

2.Transportlock7.Rollbar

3.Parkingbrakelever8.Motion-controllevers

4.Controls9.Casterwheel

5.Seatbelt

6.Fueltank

10.Mowerdeck

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe
engineandoperatethemachine(Figure4andFigure5).

1.PTOSwitch

2.Throttlecontrol5.Ignitionswitch

3.Malfunctionindicatorlight
(MIL)

4.Hour
meter/safety-interlock
display

6.Fuses

HourMeter

Thehourmeterrecordsthenumberofhourstheenginehas
operated.Itoperateswhentheengineisrunning.Usethese
timesforschedulingregularmaintenance(Figure6).

FuelGauge

LocatedontheLPGfueltank.

ThisgaugemonitorstheamountofliquidLPGinthefuel
tank.

SafetyPressureReliefValve

ThereliefvalveislocatedontheLPGfueltank(Figure7).

Thesafetypressurereliefvalverelievestheexcesspressure
intheLPGtank.

Important:Thisvalvehasaprotectiveplasticcap
thatshouldneverberemoved.Ifthecapisdamaged
ormissing,contacttrainedandqualiedpersonnel
immediately.

LPGCylinderBrackets

Thebracketsarelocatedontheenginedeck.

TheLPGcylinderbracketsareusedtofastentheremovable
LPGtanktothemower.

Safety-InterlockIndicators

Thesymbolsonthehourmeterindicatewithablacktriangle
thattheinterlockcomponentisinthecorrectposition(Figure

6).

14

BatteryIndicatorLight

g013439

1

2

3

IftheignitionkeyisturnedtotheOnpositionforafew
seconds,thebatteryvoltagewillbedisplayedinthearea
wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturnedonand
whenthechargeisbelowthecorrectoperatinglevel(Figure

6).

Figure6

ElectronicControlUnitMalfunction
IndicatorLight

Theelectroniccontrolunit(ECU)continuouslymonitorsthe
operationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the
malfunctionindicatorlight(MIL)isilluminated.

TheMIListheredlightlocatedintherightconsolepanel.

OncetheMILilluminates,initialtroubleshooting
checksshouldbemade.RefertotheMILsectionunder
Toubleshooting.

Ifthesechecksdonotcorrecttheproblem,furtherdiagnosis
andservicingbyanAuthorizedServiceDealerisnecessary.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesis
availableforusewiththemachinetoenhanceandexpand
itscapabilities.ContactyourAuthorizedServiceDealeror
Distributororgotowww .Toro.comforalistofallapproved
attachmentsandaccessories.

1.Batterylight

2.Hourmeter

3.Safety-interlocksymbols

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)isusedtoengagetheelectric
clutchanddrivethemowerblades.Pulltheswitchupto
engagethebladesandrelease.Todisengagetheblades,
pushtheblade-controlswitch(PTO)downormovea
motion-controlleverintotheneutral-lockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhasthree
positions:Start,Run,andOff.

Motion-ControlLevers

Themotion-controlleversareusedtodrivethemachine
forward,reverse,andturneitherdirection.

Neutral-LockPosition

Theneutral-lockpositionisusedwiththesafety-interlock
systemtoengageandtodetermineneutralposition.

FuelShutoffValve

Closethefuelshutoffvalveonthecylindertankwhen
transportingorstoringthemower.

15

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Width:

60-inchDeck72-inchDeck

WithoutDeck

DeectorUp156.8cm(61.7

DeectorDown192.2cm(75.7

134.6cm(53.0
inches)

inches)

inches)

150.1cm(59.1
inches)

187cm(73.6
inches)

222.4cm(87.6
inches)

TankTypeandRelling

Note:TheLPGtankusedonthismowerisaspecialtank
withinternalbafesdesignedforthisapplication.

•HorizontalTankSpecications:

–TankMaterial:Aluminum

–Capacity:43.5lb

–Disconnectcoupling:LefthandACMEthreaded

–FuelWithdrawal:Vapor

–FuelShutoffValve:Rotateclockwisetoclose.

–Typeoffuel:HD5gradepropane

Length:

60-inchDeck72-inchDeck

RollBar-Up

RollBar-Down

211.1cm(83.1
inches)

215.4cm(84.8
inches)

Height:

RollBar-UpRollBar-Down

179.1cm(70.5inches)118.9cm(46.8inches)

Weight:

60-inchDeck72-inchDeck

ZMasterriding
mower

569kg(1255lb)612kg(1350lb)

218.7cm(86.1
inches)

223.0cm(87.8
inches)

•Newtanksmustbeproperlylledbytrainedandqualied

personnel.

•OnlyusetanksrecommendedbyToro.Failuretodoso

willresultinimproperoperationofthefuelsystem.

WARNING

Useofa“forklift”typeliquidwithdrawaltankwill
resultinicingorfreezingoftheLPGregulatorand
preventtheenginefromoperating.

Thismayalsoresultinpermanentfuelsystem
damageandthereleaseofhighlyammable
propaneliquidorvapor.

16

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

AddingFuel

WhatisLPG?LPGstandsforliqueedpetroleumgasandis
morecommonlycalledpropane.LPGisaliquidfuelthatis
storedinatankunderpressure.Beforetheliquidleavesthe
tank,itisconvertedintoavapor.SinceLPGisstoredasboth
liquidandgas,itmayleakfromjointsorconnectionsthat
arenotsealedproperly.LPGbecomesammablewhenit
ismixedwithair.

TheLPGinformationinthisoperator'smanualisprovided
onlyasaguide.ConsulttheNFP A58:LiqueedPetroleum
GasCode,2008Editionforadditionalsafetyinformation.
ThisNationalFireProtectionAssociation(NFPA)code
pertainstothehandling,storing,transporting,andusageof
LPG.

DANGER

LPGfuelisextremelyammableandvaporsare
explosive.

AreorexplosionfromLPGfuelcanburnyou,
others,andcausepropertydamage.

•Neversmokearoundfueltank(s)andstayaway
fromanopenameorwherefumesmaybe
ignitedbyaspark.

•Extinguishallsourcesofsparkoramewhen
approachingLPGtanksormowers.The
hazardincreasesforenclosedtrailersorstorage
locationswherevaporleakagemayoccurand
collect.

•LPGisheavierthanairandmayaccumulatein
lowlyingareas,suchasditches,drains,orpits.

•LPGtank(s)shouldbelledbytrainedand
qualiedpersonnelonly.

Typeoffuel:HD5gradepropane

CAUTION

Undernocircumstancesshouldpropanetanksthat
arelledbeyond80%capacitybeusedinservice.

Theuseofoverlledtanksmayresultintherelease
ofhighlyconcentratedandextremelyammable
liquidpropane.Refertothe(page)section.

•Nevertamperwithorrepairthetank(s);contact
trainedandqualiedpersonnel.

•Donotchangethetank(s)whentheengineis
running.

•Beforedisconnectingthehoses,closethefuel
valvesonallofthetanksandallowtheengineto
rununtilitstopstopurgealloftheLPGvapors
fromthesystem.

•Storethetank(s)awayfromheat,sparks,or
openames.

•Donotoperatewithouttheentireexhaust
systeminplaceandinproperworkingcondition.

17

DANGER

G021497

1

2

3

4

LPGvaporsandliquidescapingfromthetankmay
causeseriousinjuryordeath.V aporsorliquidmay
causesuffocation,freezingoftissue,orfrostbite.

•Storeandservicethemowerinawellventilated
area.

•AnapprovedLPGdetectorinstalledintrailers
andstorageareasisrecommended.

•LPGisheavierthanairandmayaccumulatein
lowlyingareas,suchasditches,drains,orpits.

•Avoidbreathinginvapors.

•KeepLPGvaporsandliquidawayfromvent
valves.

•KeepLPGvaporsandliquidawayfromyour
eyesandskin.

•Contacttrainedandqualiedpersonnelifthe
tankshowssignsoffrostedareas,makesa
hissingsound,oremitsafoulodor.

•Obtainimmediatemedicalattentionifvaporsor
liquidcomeincontactwithyoureyesorskin.

Ifhandtighteningdoesnotstopaleak,contacttrained
andqualiedpersonnelimmediately .

1.Stopthemachineonlevelground,disengagethe
blade-controlswitch(PTO),movethemotion-control
leverstotheneutrallockedposition,andsetthe
parkingbrake.

2.Waitforallmovingpartstostopbeforeleavingthe
operatingposition.

3.Withtheenginerunning,closethefuelvalveonthe
tank.

4.Runtheengineuntilitstops.

Note:Thispurgesallvaporsfromthehose.

5.Removethekey.

6.CarefullydisconnecttheLPGfuelhose.

DANGER

LPGfuelisextremelyammableandvaporsare
explosive.

•Incaseofretakethefollowingsteps:

1.Ifyoucansafelydoso,stoptheowofgas
asquicklyaspossible.Neverputoutthe
ameunlessthegascanbeshutoff.

2.NotifytheFireDepartmentandclearthe
immediateareaofallpeople.

1.LPGfuelhoseconnection
tting

2.Tankvalve

3.Whenthegasowisstopped,putoutthe
re.Usuallywhenowofgasiscutoff,
rewillautomaticallystop.

7.Unlatchthecylinderbracketsandremovethetank.

4.Ifgasowcannotbeimmediatelystopped,
directwateronthetankstokeepthem
cool,but

•Storagelocationsandtrailersshouldbe

do not

putoutthere.

equippedwithatleastoneapprovedportable
reextinguisherthathasaminimumcapacity
of8.2kg(18lb)drychemicalwithaB:Crating.
DonotuseCarbonT etrachlorideextinguishers
(Pyreneetc.).

WARNING

Fuelsystemcomponentsareunderhigh
pressure.Theuseofdamagedorimproper
componentscancausesystemfailure,fuel
leakage,andpossibleexplosion,whichmay
resultinseriousinjuryordeath.

•Donotattempttorepairormodifythe
valves,ttings,orothertankcomponents.

•OnlyusetheToroapprovedLPGtank,

ChangingtheLPGTank

ChangetheLPGtankoutdoorsinawellventilatedarea.

ttings,andhosesthatweredesignedfor
yourmower.

Figure7

3.Fuelgauge

4.Safetypressurerelief
valve

Important:Onlyhandtightentankconnectiontting.
Overtighteningbytheuseoftoolsmaycausedamage.

8.Inspectthelledtankvalveandttingopeningsfor
dirt,debris,ordamage.

18

9.Inspectthetankhoseconnectionttingfordamaged

G021393

ormissingo-rings.

10.Makesurethatthereplacementtanktypeandsize
matchthetankspecicationdecal.

11.Alignthecenterholeoverthemountingpinthatpoints
straightuponthemowerasshowninFigure8.

UsingtheRolloverProtection System(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keeptheroll
barinthefullyraisedlockedpositionandusethe
seatbelt.

Ensurethattherearpartoftheseatissecuredwith
theseatlatch.

WARNING

Thereisnorolloverprotectionwhentherollbaris
inthedownposition.

•Lowertherollbaronlywhenabsolutely
necessary.

Figure8

1.Cylinderbrackets3.Centerhole

2.Mountingpin

Important:Thevalvesandgaugesmaynot
functionproperlyiftheLPGtankisnotinstalled
correctly.

12.Latchthecylinderbracketsandmakesurethatthetank
issecurelyfastenedtothemower.

13.Carefullyconnectthefuelhose.Makesurethehoseis
notkinked.

14.Slowlyopenthefuelvalvetoequalizethepressurein
thetank.

Note:Ifthefuelvalveisopenedtooquickly,the
pressurereliefvalveisequippedwithabackpressure
checkvalvethatwillshutoffthefuelsupply.Ifthis
happens,closethefuelvalvecompletelyandwait5
seconds.

15.Checkforleaksasdescribedin(page).

•Donotweartheseatbeltwhentherollbaris
inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearancepermits.

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

Important:Lowertherollbaronlywhenabsolutely
necessary.

Important:Ensurethattherearpartoftheseatis
securedwiththeseatlatch.

1.Tolowertherollbar,applyforwardpressuretothe
upperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sotheyare
notengaged(Figure9).

3.Lowertherollbartothedownposition(Figure9).

CheckingtheEngine-OilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoCheckingthe

Engine-OilLevel(page37).

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mowerdecks
anddrivesystemshavehigherfrictionwhennew,placing
additionalloadontheengine.Allow40to50hoursof
break-intimefornewmachinestodevelopfullpowerand
bestperformance.

19

g021418

2 1

3

4

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthesafety
section.Knowingthisinformationcouldhelpyouor
bystandersavoidinjury.

DANGER

Operatingonwetgrassorsteepslopescancause
slidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers,
whichmayresultinseriousinjury,deathor
drowning.

Thereisnorolloverprotectionwhentherollbaris
down.

Alwayskeeptherollbarinthefullyraisedand
lockedpositionandusetheseatbelt.

Readandfollowtherolloverprotectioninstructions
andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

Figure9

1.ROPSknob

2.PullROPSknoboutand
rotate90degrees

3.Rollbarintheupright
position

4.Rollbarinthefolded
position

4.Toraisetherollbar,raisetherollbartotheoperate
position,rotatetheknobssotheymovepartiallyinto
thegrooves(Figure9).

5.Raisetherollbartothefulluprightpositionwhile
pushingontheupperrollbarandthepinswillsnap
intopositionwhentheholesalignwiththepins(Figure

9).Pushontherollbarandensurethatbothpinsare

engaged.

Important:Alwaysusetheseatbeltwiththeroll
barinthefullyraisedposition.

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure10

1.SafeZone-usethe
ZMasterhereonslopes

20

lessthan15degreesor
atareas.

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

3.Water

CAUTION

G009027

1

2

g027334

g027335

G008945

G009174

Thismachineproducessoundlevelsinexcessof
85dBAattheoperatorsearandcancausehearing
lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,hands,feet,
andheadisrecommended.

Figure11

1.Wearsafetyglasses

2.Wearhearingprotection

ReleasingtheParkingBrake

Figure13

OperatingtheMower Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)startsandstopsthemower
bladesandanypoweredattachments.

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor
leaveitunattended.

SettingtheParkingBrake

WARNING

Parkingbrakemaynotholdmachineparkedona
slopeandcouldcausepersonalinjuryorproperty
damage.

Donotparkonslopesunlesswheelsarechocked
orblocked

EngagingtheBlade-ControlSwitch
(PTO)

Note:Engagingtheblade-controlswitch(PTO)withthe

throttlepositionathalforlesswillcauseexcessivewearto
thedrivebelts.

Figure14

DisengagingtheBlade-ControlSwitch
(PTO)

Figure12

Figure15

21

OperatingtheThrottle

G008946

START

RUN

STOP

G008947

G027421

A

B

C

D

E

F

ThethrottlecontrolcanbemovedbetweentheFastand
Slowpositions(Figure16).

Usethefastpositionwhenturningonthemowerdeckwith
theblade-controlswitch(PTO).

Figure16

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition(Figure17).
Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformorethan5
secondsatatime.Iftheenginefailstostartallow
a15secondcool-downperiodbetweenattempts.
Failuretofollowtheseinstructionscanburnout
thestartermotor.

Note:Thefuelvalveislocatedonthetopendofthe
LPGtank.Ifthefuelvalveisopenedtooquickly,the
pressurereliefvalveisequippedwithabackpressure
checkvalvethatwillshutoffthefuelsupply.Ifthis
happens,closethefuelvalvecompletelyandwait5
seconds.

3.Movethemotioncontrolstoneutrallockedposition.

4.Settheparkingbrake;refertoSettingtheParking

Brake(page21).

5.Movetheblade-controlswitch(PTO)totheoff
position(Figure18).

6.Movethethrottlelevertothe3/4throttleposition
betweentheslowandfastpositions(Figure18).

Note:Additionalstartingcyclesmayberequired
whenstartingtheengineforthersttimeafterthefuel
systemhasbeenwithoutfuelcompletely.

Figure17

2.Turntheignitionkeytostoptostoptheengine.

StartingandStoppingthe Engine

StartingtheEngine

Figure18

7.Turntheignitionkeytothestartposition(Figure17).
Whentheenginesstarts,releasethekey .

1.RaisetheROPSupandlockintoplace,sitontheseat,
andfastentheseatbelt.

2.Slowlyopenthefuelvalvetoequalizethepressurein
thetank.

22

StoppingtheEngine

G027422

A

B

C

D

E

G013672

1

TheSafety-InterlockSystem

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60seconds
beforeturningtheignitionswitchoff.

CAUTION

Ifsafety-interlockswitchesaredisconnectedor
damagedthemachinecouldoperateunexpectedly
causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches
dailyandreplaceanydamagedswitchesbefore
operatingthemachine.

UnderstandingtheSafety-Interlock
System

Thesafety-interlocksystemisdesignedtopreventtheengine
fromstartingunless:

•Theparkingbrakeisengaged.

•Theblade-controlswitch(PTO)isdisengaged.

•Themotion-controlleversareintheneutrallocked

position

Thesafety-interlocksystemalsoisdesignedtostopthe
enginewhenthetractioncontrolsaremovedfromthelocked
positionwiththeparkingbrakeengagedorifyourisefrom
theseatwhenthePTOisengaged.

Figure19

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine,as
fuelleakagemayoccur.Settheparkingbrakebefore
transporting.Makesuretoremovethekeyasthefuel
pumpmayrunandcausethebatterytolosecharge.

Thehourmeterhassymbolstonotifytheuserwhenthe
interlockcomponentisinthecorrectposition.Whenthe
componentisinthecorrectposition,atrianglewilllightup
inthecorrespondingsquare.

Figure20

1.Triangleslightupwhentheinterlockcomponentsareinthe
correctposition

TestingtheSafety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethemachine
eachtime.Ifthesafetysystemdoesnotoperateasdescribed
below,haveanAuthorizedServiceDealerrepairthesafety
systemimmediately.

1.Sittingontheseat,engagetheparkingbrake,andmove
theblade-controlswitch(PTO)toon.Trystartingthe
engine;theengineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrake,andmove
theblade-controlswitch(PTO)tooff.Moveeither

23

motion-controllever(outofneutrallockedposition).
Trystartingtheengine;theengineshouldnotcrank.
Repeatforothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,move
theblade-controlswitch(PTO)tooff,andmovethe
motion-controlleverstoneutral-lockposition.Now
starttheengine.Whiletheengineisrunning,releasethe
parkingbrake,engagetheblade-controlswitch(PTO)
andriseslightlyfromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move
theblade-controlswitch(PTO)tooff,andmovethe
motion-controlleverstoneutral-lockposition.Now
starttheengine.Whiletheengineisrunning,center
eithermotioncontrolandmove(forwardorreverse);
theengineshouldstop.Repeatforothermotion
control.

5.Sittingontheseat,disengagetheparkingbrake,move
theblade-controlswitch(PTO)tooff,andmovethe
motion-controlleverstoneutral-lockposition.Try
startingtheengine;theengineshouldnotcrank.

DrivingForwardorBackward

UsingtheMotion-ControlLevers

Thethrottlecontrolregulatestheenginespeedasmeasured
inrpm(revolutionsperminute).Placethethrottlecontrolin
thefastpositionforbestperformance.Alwaysoperateinthe
fullthrottlepositionwhenmowing.

CAUTION

Machinecanspinveryrapidly.Operatormaylose
controlofmachineandcausepersonalinjuryor
damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp
turns.

Figure21

1.Motion-control
lever-neutral-lockposition

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

DrivingForward

Note:Theenginewillstopifthetractioncontrolleversare

movedwiththeparkingbrakeengaged.

Tostop,pullthemotion-controlleverstotheneutralposition.

1.Releasetheparkingbrake;refertoReleasingthe

ParkingBrake(page21).

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotion-controllevers
forward(Figure22).

24

G008952

Figure22

G008953

StoppingtheMachine

Tostopthemachine,movethetractioncontrolleversto
neutralandmovetolockedposition,disengagethepower
takeoff(blade-controlswitch(PTO),andturntheignition
keytooff.

Settheparkingbrakewhenyouleavethemachine;referto

SettingtheParkingBrake(page21).Remembertoremove

thekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhileitis
unattended.

Alwaysremovetheignitionkeyandsettheparking
brakewhenleavingthemachineunattended,even
ifjustforafewminutes.

AdjustingtheHeightofCut

UsingtheTransportLock

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotion-controllevers
rearward(Figure23).

Thetransportlockhas2positionsandisusedwiththedeck
liftpedal.Thereisalockpositionandaunlockpositionfor
thetransportposition.Thetransportlockisusedwiththe
deckliftpedal.RefertoFigure24

Figure23

25

AdjustingtheHeight-of-CutPin

Theheight-of-cutisadjustedfrom25to140mm(1to
5-1/2inches)in6mm(1/4inch)incrementsbyrelocating
theclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfootandraisethe
mowerdecktothetransportposition(alsothe140mm
(5-1/2inch)cuttingheightposition)(Figure25).

3.Toadjust,rotatethepin90degreesandremovethepin
fromtheheight-of-cutbracket(Figure25).

4.Selectaholeintheheight-of-cutbracketcorresponding
totheheight-of-cutdesiredand,insertthepin(Figure

25).

5.Pushonthedecklift,pullbackonthetransportlock,
andslowlylowerthemowerdeck.

Figure24

TransportLockPositions

1.Transportlock3.Unlockposition—doesnot
lockthemowerdeckinto
transportposition

2.Lockposition—mower

deckwilllockintotransport
position

Figure25

1.Deckliftpedal

2.Cutofheightpin

3.Transportlock

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,itisrecommended
toadjusttheheightoftheanti-scalprollers.

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

26

Figure26

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

AdjustingtheFlowBafeCam
Locks

Thisprocedureisapplicableonlytomachineswiththeow
bafelocks.Certainmodelswillhavenutsandboltsin-place
oftheowbafelocksandcanbeadjustedthesame.

Themowerdischargeowcanbeadjustedfordifferenttypes
ofmowingconditions.Positionthecamlocksandbafeto
givethebestqualityofcut.

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition,
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Toadjustthecamlocks,swingtheleveruptoloosen
thecamlock(Figure29).

4.Adjustthebafeandcamlocksintheslotstothe
desireddischargeow.

5.Swingtheleverbackovertotightenthebafeandcam
locks(Figure29).

6.Ifthecamlocksdonotlockthebafeintoplaceorit
istootight,loosentheleverandthenrotatethecam
lock.Adjustthecamlockuntilthedesiredlocking
pressureisachieved.

Figure27

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

Figure28

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

Figure29

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse.
Adjustmentswillvarybygrasstype,moisturecontent,and
heightofgrass.

Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggesteduseforthis
positionisasfollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

27

•Forsmallergrassclippings.

g019754

g019755

•Propelsgrassclippingsfartherawayfromthemower.

Figure30

PositionB

Usethispositionwhenbagging.Alwaysalignitwiththe
bloweropening.

Figure32

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positiontheseat
whereyouhavethebestcontrolofthemachineandaremost
comfortable.

Figure31

PositionC

Thisisthefullopenposition.Thesuggesteduseforthis
positionisasfollows.

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

Toadjust,movetheleversidewaystounlockseat(Figure33).

Figure33

UnlatchingtheSeat

•ThispositionissimilartothebenetsoftheToroSFS

mower.

Figure34

1.Seatlatch2.Seat

28

ChangingtheSeatSuspension

g019768

1

G021491

Theseatisadjustabletoprovideasmoothandcomfortable
ride.Positiontheseatwhereyouaremostcomfortable.

Toadjustit,turntheknobinfronteitherdirectiontoprovide
thebestcomfort(Figure35).

Figure35

1.Seatsuspensionknob

3.Rotatethereleasevalveleversverticallytopushthe
machine(Figure36).

Note:Thisallowshydraulicoiltoby-passthepump
enablingthewheelstoturn.

4.Disengageparkingbrakebeforepushingthemachine.

Figure36

UsingtheDriveWheelRelease Valves

WARNING

Handsmaybecomeentangledintherotatingdrive
componentsbelowtheenginedeck,whichcould
resultinseriousinjury.

Stoptheengine,removethekey ,andallowall
movingpartstostopbeforeaccessingthedrive
wheelreleasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome
veryhot.Touchingahotengineorhydraulicdrive
unitscancausesevereburns.

Allowtheengineandhydraulicdriveunitstocool
completelybeforeaccessingthedrivewheelrelease
valves.

Thedrivewheelreleasevalvesarelocatedinthebackofeach
hydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefullyhorizontal
positionwhenoperatingthemachineorseveredamagetothe
hydraulicsystemcanoccur.

1.DisengagethePTO(blade-controlswitch)andturn
theignitionkeytooff.

2.Movetheleverstoneutrallockedposition,apply
parkingbrake,andremovethekey.

1.Verticalpositiontopush
themachine

5.Rotatethereleasevalvelevershorizontallytorunthe
machine(Figure36).

2.Horizontalpositiontorun
themachine

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

DANGER

Withoutagrassdeector,dischargecover,or
completegrasscatcherassemblymountedin
place,youandothersareexposedtobladecontact
andthrowndebris.Contactwithrotatingmower
blade(s)andthrowndebriswillcauseinjuryor
death.

•Neverremovethegrassdeectorfromthemower
becausethegrassdeectorroutesmaterialdown
towardtheturf.Ifthegrassdeectorisever
damaged,replaceitimmediately .

•Neverputyourhandsorfeetunderthemower.

•Nevertrytoclearthedischargeareaormower
bladesunlessyoumovethepowertakeoff
(PTO)blade-controlswitchtotheoffposition,
rotatetheignitionkeytotheoffposition,and
removethekey .

•Makesurethatthegrassdeectorisinthedown
position.

29

TransportingtheMachine

G027423

Useaheavy-dutytrailerortrucktotransportthemachine.
Ensurethatthetrailerortruckhasallnecessarybrakes,
lighting,andmarkingasrequiredbylaw .Readallthesafety
instructions.Thisinformationcouldhelpyou,yourfamily,
pets,orbystandersavoidinjury.

Trailersshouldbeequippedwithatleastoneapproved
portablereextinguisherhavingaminimumcapacityof8.2
kg(18lb)drychemicalwithaB:Crating.Donotusecarbon
tetrachlorideextinguishers(Pyreneetc.).

WARNING

Drivingonthestreetorroadwaywithoutturn
signals,lights,reectivemarkings,oraslow
movingvehicleemblemisdangerousandcanlead
toaccidentscausingpersonalinjury.

Donotdrivethemachineonapublicstreetor
roadway.

•Besurethatthefuelvalveisclosedonthetank(s).

•PlacespareLPGtank(s)inaDOTapprovedstoragecage.

–Transportthetanksinanupright,vertical,andsecure

positiontominimizemovement,tipping,orphysical
damagerelativetoothertanksortothestoragecage
whileintransit.

–Placetankssothatvalves,ttings,orgaugesare

protectedfromphysicaldamageduringtransport.

•Placetank(s)inawell-ventilatedtrailer.

•Donotstorethetank(s)ormachinewithtank(s)inan

areawherethetemperaturecanriseabove120°F(49°C).
Ifthetemperatureexceedsapproximately160°F(71°C),
thetankwillreleasehighlyammablepropanevapor.See
PreparationintheSafetySection.

•DonottransportLPGtank(s)inthepassengerspaceof

avehicle.

•Donottransportleakingfueltanks.

•Trailersmusthaveappropriatemarkingstotransport

LPG.

•FollowNFPA58andstateandlocalregulationsfor

transportingLPG.

Figure37

1.Tractionunittiedownloops

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicleand
connectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,and
closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto
securelyfastenthemachinetothetrailerortruckwith
straps,chains,cable,orropes(Figure37).

30

LoadingtheMachine

g028043

g027996

5

1

2

6

Useextremecautionwhenloadingorunloadingmachines
ontoatraileroratruck.Useafull-widthrampthatiswider
thanthemachineforthisprocedure.Backuprampsand
driveforwarddownramps(Figure38).

Figure38

1.Backupramps

2.Driveforwarddownramps

Important:Donotusenarrowindividualrampsfor
eachsideofthemachine.

Ensuretherampislongenoughsothattheanglewiththe
grounddoesnotexceed15degrees(Figure39).Onat
ground,thisrequiresaramptobeatleast4timesaslongas
theheightofthetrailerortruckbedtotheground.Asteeper
anglemaycausemowercomponentstogetcaughtastheunit
movesfromtheramptothetrailerortruck.Steeperangles
mayalsocausethemachinetotiporlosecontrol.Ifloading
onornearaslope,positionthetrailerortrucksothatitis
onthedownsideoftheslopeandtherampextendsupthe
slope.Thiswillminimizetherampangle.

WARNING

Loadingamachineontoatrailerortruckincreases
thepossibilityoftip-overandcouldcauseserious
injuryordeath.

•Useextremecautionwhenoperatingamachine
onaramp.

•EnsurethattheROPSisintheuppositionand
usetheseatbeltwhenloadingorunloadingthe
machine.EnsurethattheROPSwillclearthe
topofanenclosedtrailer.

•Useonlyafull-widthramp;donotuseindividual
rampsforeachsideofthemachine.

•Donotexceeda15-degreeanglebetweenthe
rampandthegroundorbetweentherampand
thetrailerortruck.

•Ensurethelengthoframpisatleast4timesas
longastheheightofthetrailerortruckbedto
theground.Thiswillensurethatrampangle
doesnotexceed15degreesonatground.

•Backuprampsanddriveforwarddownramps.

•Avoidsuddenaccelerationordecelerationwhile
drivingthemachineonarampasthiscould
causealossofcontroloratip-oversituation.

1.Full-widthrampinstowed
position

2.Sideviewoffull-width
rampinloadingposition

3.Notgreaterthan
15degrees

Figure39

4.Rampisatleast4times
aslongastheheightof
thetrailerortruckbedto
theground

5.H=heightofthetraileror
truckbedtotheground

6.Trailer

31

OperatingTips

FastThrottleSetting

cuttingheighthigherthanusualandcutthegrassatthis
setting.Thencutthegrassagainusingthelower,normal
setting.

Forbestmowingandmaximumaircirculation,operate
theengineatthefastthrottleposition.Airisrequiredto
thoroughlycutgrassclippings,sodonotsettheheight-of-cut
solowastototallysurroundthemowerbyuncutgrass.
Alwaystrytohaveonesideofthemowerfreefromuncut
grass,whichallowsairtobedrawnintothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethatthe
cuttingheightofthemowerdoesnotscalpanyuneven
ground.However,thecuttingheightusedinthepastis
generallythebestonetouse.Whencuttinggrasslongerthan
6inchestall,youmaywanttocutthelawntwicetoensure
anacceptablequalityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.Cutting
morethanthatisnotrecommendedunlessgrassissparse,or
itislatefallwhengrassgrowsmoreslowly.

AlternatingtheMowingDirection

StoppingtheMachine

Ifyoumuststopthemachine’sforwardmotion,aclumpof
grassclippingsmaydropontoyourlawn.Toavoidthis,move
ontoapreviouslycutareawiththebladesengaged.

KeeptheUndersideoftheMowerClean

Cleanclippingsanddirtfromtheundersideofthemower
aftereachuse.Ifgrassanddirtbuildupinsidethemower,
cuttingqualitywilleventuallybecomeunsatisfactory.

MaintainingtheBlades

Maintainasharpbladethroughoutthecuttingseasonbecause
asharpbladecutscleanlywithouttearingorshreddingthe
grassblades.Tearingandshreddingturnsgrassbrownat
theedges,whichslowsgrowthandincreasesthechanceof
disease.Checkthecutterbladesdailyforsharpness,andfor
anywearordamage.Filedownanynicksandsharpenthe
bladesasnecessary.Ifabladeisdamagedorworn,replaceit
immediatelywithagenuineT ororeplacementblade.

Alternatemowingdirectiontokeepthegrassstanding
straight.Thisalsohelpsdisperseclippingswhichenhances
decompositionandfertilization.

MowatCorrectIntervals

Normally,mowevery4days.Grassgrowsatdifferentratesat
differenttimes.Tomaintainthesamecuttingheight,which
isagoodpractice,mowmoreofteninearlyspring.Asthe
grassgrowthrateslowsinmidsummer,mowlessfrequently.
Ifyoucannotmowforanextendedperiod,rstmowata
highcuttingheight;thenmowagain2dayslateratalower
heightsetting.

CuttingSpeed

Toimprovecutquality,useaslowergroundspeedincertain
conditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthemower
youpreviouslyused,raisethecuttingheighttoensurethat
uneventurfisnotcuttooshort.

CuttingLongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan
normal,orifitcontainsahighdegreeofmoisture,raisethe

32

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

Every40hours

Every50hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Checktheparkingbrakeadjustment.

•Changethehydraulicltersandhydraulicoilwhenusinganytypeofoil.

•Checkthesafetysystem.

•Checktheengineoillevel.

•ChecktheLPGtankandcomponents.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunitshrouds.

•Checkthemowerblades.

•Cleanthemowerdeck.

•ChecktheLPGhoses,regulatorandconnections.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

Every100hours

Every150hours

Every200hours

Every250hours

Every300hours

Every500hours

Every600hours

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Check,cleanandregapthesparkplug.

•Checkandcleanenginecoolingnsandshrouds.

•Inspecttheprimarylterandairinletscreen.

•Changetheengineoillter.

•ChangethehydraulicltersandhydraulicoilwhenusingMobil®1oil(moreoftenin
dirtyordustyconditions).

•Replacetheprimaryairlter.(moreoftenindustyorsandyconditions)

•Checktheairlter.

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Adjustthecasterpivotbearing.

•Checktheparkingbrakeadjustment.

•ChangethehydraulicltersandhydraulicoilwhenusingToro®HYPR-OIL™500
hydraulicoil(moreoftenindirtyordustyconditions).

•Replacetheairlter.

Monthly

Yearly

•Checkthebattery .

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs.

Yearlyorbeforestorage

•Paintanyofthechippedsurfaces.

•Checkallofthemaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

33

CAUTION

g021419

G009029

Ifyouleavethekeyintheignitionswitch,someonecouldstarttheengineandseriouslyinjureyouor
otherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare
extremelydustyorsandy.

GreaseType:No.2generalpurpose,lithium-basedor
molybdenum-basedgrease

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Cleanthegreasettingswitharag.Makesuretoscrape
anypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease
intothettingsuntilgreasebeginstooozeoutofthe
bearings.

5.Wipeupanyexcessgrease.

GreasingtheMower

ServiceInterval:Every50hours—Greasethemowerdeck

spindlesandidlerarm.

Yearly—Greasethepumpbeltidlerarm.

Yearly—Greasethefrontcasterpivots(moreoftenin
dirtyordustyconditions).

Yearly—Repackthefrontcasterwheelbearings(more
oftenindirtyordustyconditions).

Important:Makesurethatthecuttingunitspindlesare
fullofgreaseweekly.

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition,
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Greasethemowerdeckidlerpulleypivotuntilgrease
comeoutthebottom(Figure41).

4.Greasethethreespindlebearingsuntilgreasecomes
outthelowerseals(Figure41).

AddingLightOilorSprayLubrication

ServiceInterval:Every100hours—Lubricatethemower

deckliftpivots.

Lubricatethemowerdeckliftpivots.

Figure40

Figure41

5.Greasethedrivebeltidlerarm(Figure41).

34

Figure42

g027413

6.Removethedustcapandadjustthecasterpivots.
Keepthedustcapoffuntilgreasingisdone.Referto

AdjustingtheCasterPivotBearing(page46).

LubricatingtheCasterWheel Hubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop,and
removethekey.Engagetheparkingbrake.

Figure44

1.Sealguard2.Spacernutwithwrench
ats

7.Removethehexplug.Threadagreasettingintothe
hole.

8.Pumpgreaseintothettinguntilitoozesoutaround
thetopbearing.

9.Removethegreasettinginthehole.Installthehex
pluganddustcap(Figure43).

Figure43

2.Raisethefrontofthemachineupandsupportitwith
jackstands.

3.Removethecasterwheelfromthecasterforks.

4.Removethesealguardsfromthewheelhub.

5.Remove1ofthespacernutsfromtheaxleassembly
inthecasterwheel.

Note:Notethatthreadlockingadhesivehasbeen
appliedtolockthespacernutstotheaxle.Remove
theaxle(withtheotherspacernutstillassembledtoit)
fromthewheelassembly.

6.Pryouttheseals,andinspectthebearingsforwearor
damageandreplaceifnecessary.

7.Packthebearingswithageneral-purposegrease.

8.Insert1bearingand1newsealintothewheel.

Note:Thesealsmustbereplaced.

9.Iftheaxleassemblyhashadbothspacernutsremoved
(orbrokenloose),applyathreadlockingadhesiveto1
spacernutandthreaditontotheaxlewiththewrench
atsfacingoutward.

Note:Donotthreadthespacernutalloftheway
ontotheendoftheaxle.Leaveapproximately3mm
(1/8inch)fromtheoutersurfaceofthespacernutto
theendoftheaxleinsidethenut.

10.Inserttheassemblednutandaxleintothewheelonthe
sideofthewheelwiththenewsealandbearing.

11.Withtheopenendofthewheelfacingup,llthearea
insidethewheelaroundtheaxlefullofgeneral-purpose
grease.

12.Insertthesecondbearingandnewsealintothewheel.

35

13.Applyathreadlockingadhesivetothesecondspacer

g012996

3

4

1

2

nutandthreaditontotheaxlewiththewrenchats
facingoutward.

14.Torquethenutto8-9N-m(75-80in-lb),loosen,then
re-torqueto2-3N-m(20-25in-lb).

Note:Makesurethattheaxledoesnotextendbeyond
eithernut.

15.Installthesealguardsoverthewheelhubandinsert
thewheelintothecasterfork.Installthecasterbolt
andtightenthenutfully.

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal
injury.

Keephands,feet,face,clothing,andotherbody
partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

Important:T opreventsealandbearingdamage,check

thebearingadjustmentoften.Spinthecastertire.The
tireshouldnotspinfreely(morethan1or2revolutions)
orhaveanysideplay .Ifthewheelspinsfreely,adjustthe
torqueonthespacernutuntilthereisaslightamountof
drag.Applythreadlockingadhesive.

ServiceInterval:Every150hours

Every300hours/Yearly(whichevercomes
rst)—Replacetheprimaryairlter.(moreoftenin
dustyorsandyconditions)

Every300hours—Checktheairlter.

Every600hours—Replacetheairlter.

Note:Checktheltersmorefrequentlyiftheoperating
conditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Releasethelatchesontheaircleanerandpulltheair
inletcoverofftheaircleanerbody(Figure45).

4.Cleantheairinletscreenandcover.

5.Installtheairinletcoverandsecureitwiththelatches
(Figure45).

Figure45

1.Airinletcover3.Aircleanerbody

2.Airinletscreen4.Latch

6.Releasethelatchesontheaircleanerandpulltheair
cleanercoverofftheaircleanerbody(Figure46).

7.Cleantheinsideoftheaircleanercoverwith
compressedair.

36

8.Gentlyslidetheprimarylteroutoftheaircleaner

g012997

1

2

3

4

5

g012991

0

0

50

SAE 30

body(Figure46).

2.Carefullyslidetheprimarylteroverthesafetylter
(Figure46).

Note:Avoidknockingthelterintothesideofthe
body.

9.Removethesafetylteronlyifyouintendtoreplaceit.

Important:Neverattempttocleanthesafety
lter.Ifthesafetylterisdirty,thentheprimary
lterisdamaged.Replacebothlters.

Note:Ensurethattheprimarylterisfullyseatedby
pushingonitsouterrimwhileinstallingit.

Important:Donotpressonthesoftinsidearea
ofthelter.

3.Installtheaircleanercoverandsecurethelatches
(Figure46).

ServicingtheEngineOil

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

EngineOilCapacity:withalterchange,77ounces(2.3L);
withoutalterchange,70ounces(2.1L)

Viscosity:Seethetablebelow.

Figure46

1.Safetylter

2.Primarylter

3.Aircleanercover

10.Inspecttheprimarylterfordamagebylookinginto

4.Latch

5.Aircleanerbody

Figure47

thelterwhileshiningabrightlightontheoutsideof
thelter.Holesinthelterwillappearasbrightspots.
Ifthelterisdamaged,discardit.

Note:Useofmulti-gradeoils(5W -20,10W-30,or10W -40)
willincreaseoilconsumption.Checktheoillevelmore

ServicingthePrimaryFilter

•Replacetheprimarylterifitisdirty,bent,ordamaged.

frequentlywhenusingthem.

CheckingtheEngine-OilLevel

•Donotcleantheprimarylter.

ServiceInterval:Beforeeachuseordaily

ServicingtheSafetyFilter

Note:Checktheoilwhentheengineiscold.

Replacethesafetylter,nevercleanit.

WARNING

Important:Neverattempttocleanthesafetylter.

Ifthesafetylterisdirty,thentheprimarylteris
damaged.Replacebothlters.

InstallingtheFilters

Important:Topreventenginedamage,alwaysoperate

theenginewithbothairltersandcoverinstalled.

Note:Ifinstallingnewlters,checkeachlterforshipping
damage.Donotuseadamagedlter.

1.Toreplacethesafetylter,carefullyslideitintothe
lterbody(Figure46).

Contactwithhotsurfacesmaycausepersonal
injury.

Keephands,feet,face,clothing,andotherbody
partsawayfromthemuferandotherhotsurfaces.

Important:Donotoverllthecrankcasewithoil
becausedamagetotheenginemayresult.Donotrun
enginewithoilbelowthelowmarkbecausetheengine
maybedamaged.

1.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedposition,andsettheparkingbrake.

37

2.Stoptheengine,removethekey,andwaitforall

G021395

B

A

C

D

E

G027659

F

G

H

I J

G021395

movingpartstostopbeforeleavingtheoperating
position(Figure48).

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirtyordusty
conditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothattherearisslightlylowerthan
thefronttoensurethattheoildrainscompletely.

2.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedposition,andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Draintheengineoil(Figure49).

Figure48

Figure49

38

5.Slowlypourapproximately80%ofthespeciedoil

B

A

C

D

E

F

g027660

G021395

B

A

C D

E

F

3/4

g027477

intothellertubeandslowlyaddtheadditionaloilto
bringittotheFullmark(Figure50).

ChangingtheEngine-OilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequentlywhen
operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe

EngineOil(page38).

2.Changetheengineoillter(Figure51).

6.Starttheengineanddrivetoaatarea.Checktheoil
levelagain.

Figure50

Figure51

Note:Ensurethattheoilltergaskettouchesthe

engineandthenturnitanextra3/4turn.

3.Fillthecrankcasewiththepropertypeofnewoil;refer
toServicingtheEngineOil(page37).

39

ServicingtheSparkPlug

G021397

G021396

B

A

g027478

B

A

g027479

ServiceInterval:Every100hours

Makesurethattheairgapbetweenthecenterandside
electrodesiscorrectbeforeinstallingthesparkplug.Use
asparkplugwrenchforremovingandinstallingthespark
plug(s)andagappingtool/feelergaugetocheckandadjust
theairgap.Installanewsparkplug(s)ifnecessary.

Type:Champion

AirGap:0.75mm(0.030inch)

RemovingtheSparkPlug

1.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

®

XC12YCorequivalent

4.Removethesparkplug.

2.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedpositionandsettheparkingbrake.

3.Removethelefthydraulicunitshroudintheorder
listedwithFigure52.

Note:Thisgivesyouaccesstothefrontsparkplug.

Figure53

5.Installthelefthydraulicunitshroud(Figure52).

CheckingtheSparkPlug

Important:Nevercleanthesparkplug(s).Always

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

Ifyouseelightbrownorgrayontheinsulator,theengineis
operatingproperly .Ablackcoatingontheinsulatorusually
meanstheaircleanerisdirty.

Setthegapto0.76mm(0.030inches).

1.Pullthistabouttothe
sideinthedirectionofthe
arrow.

2.Pulltheshroudoffofthis
frametabinthedirection
ofthearrow.

Figure52

3.Pulltheshroudoffofthis
frametabinthedirection
ofthearrow.

4.Shroud

Figure54

40

InstallingtheSparkPlug

CheckingSparkArrester(if

Tightenthesparkplug(s)to22N-m(16ft.-lb).

Figure55

equipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite
gasolinevaporsevenaftertheengineisstopped.
Hotparticlesexhaustedduringengineoperation
mayigniteammablematerials.Firemayresultin
personalinjuryorpropertydamage.

Donotrefuelorrunengineunlesssparkarrester
isinstalled.

1.Stoptheengine,waitforallmovingpartstostop,and
removethekey .Engageparkingbrake.

2.Waitforthemufertocool.

3.Replacethearresterifthereareanybreaksinthescreen
orwelds.

4.Ifthescreenisplugged,removethearresterandshake
looseanyparticlesoutofthearresterandcleanthe
screenwithawirebrush(soakthearresterinsolventif
necessary).Installarresterontheexhaustoutlet.

41

FuelSystem

ammoniawillcausethettingstocorrodeand
leak.)

Maintenance

InspectingtheLPGSystem

ServiceInterval:Beforeeachuseordaily—ChecktheLPG

tankandcomponents.

Every40hours—ChecktheLPGhoses,regulatorand
connections.

ItisveryimportanttochecktheLPGtankandcomponents
forwearorleaks.

Important:Nevercheckforleaksusinganopename.

Important:Neverusebarehandswhencheckingthe

ttingorvalve.EscapingLPGvaporandliquidfreezes
skinoncontact.

•Inspectingbeforeeachuse:

–Visuallyinspectthetank,hose,andttingandbealert

toafoulodorcomingfromthetank.

–TheLPGtankshouldbefreeofdentsordamage.

Ifthetankshowsignsofdentsordamage,replace
itimmediately.

–Checkthevalveandttingopeningsfordirtand

debris.

–Slowlyopenthevalveallthewayandlistenfora

continuoushissfromtheregulator,itmayindicate
aleak.

–LPGhasarotteneggorskunksmelladdedtoitto

helpdetectagasleak.Ifyoudetectagasleak:

◊TurnofftheLPGvalveifyoucansafelydoso.

◊Leavethearea.

◊Contacttrainedandqualiedpersonnel

immediately.

–Donotuseifthehosesareabraded,damaged,kinked,

orattened.

–Makesurethatthetankissecurelymountedtothe

mower.Ifthetankisloose,thehoseorttingsmay
leak.

•Inspectingwitheachtankchange:

–Checkallgauges,ttings,andvalvesfordamage.

–Lookfordeterioration,wornormissingo-ringson

thetankconnectiontting.

–InspecttheLPGtankandthefuelconnectionjoint

forleaks.Usethefollowingprocedurebelowto
detectleaks:

◊Applyanapprovedleakdetectorsolution,

obtainedfromatrainedandqualiedLPG
distributor,orathicknon-ammoniasoapywater
solution(50%non-ammoniasoapand50%
water).(Aleakdetectorsolutionthatcontains

◊Usingasmallbrushorspraybottle,applythe

solutionaroundallthettingsoftheLPGtank
andthefuelconnectionjoint.

◊Slowlyopenthegasvalveahalf-turn.

◊Ifbubblesaredetected,thejointorttinghas

aleak.Shutoffthevalve,tightentheleaking
connection,andslowlyopenthevalveagain.If
bubblesstillappear,donotusethetank.Ifitis
safetodoso,removethetankfromyourmower;
otherwise,contacttrainedandqualiedpersonnel
immediately.

◊Ifnobubblesaredetected,theLPGtankmaybe

used.

•Inspectingweekly:

–ChecktheLPGhoses,regulator,andconnectionsfor

damageordeterioration.

–ChecktheLPGhoses,regulator,andconnectionsfor

leaksatalljointsusingthesamemethodasdescribed
intheprevioussection.

–Followalltheinspectionchecksasspeciedinthe

twopreviousinspectionsections.

•TankRequalication:

–USDOT(UnitedStatesDepartmentof

Transportation)regulationsrequireLPGtankstobe
inspected,requalied,andmarkedwithin12yearsof
themanufacturedateandonaregularbasisthereafter.
Typicallythisoccurswhenthetankisrelled;contact
atrainedandqualiedLPGtankproviderformore
details.

–DonotlltheLPGtankifitisbeyondthe

requalicationperiod.

–DonotlldamagedorrustedLPGtanks.

ServicingtheElectronicFuel InjectionSystem

Thismachinecontainsanelectronicfuelinjectionsystem.It
controlsthefuelowunderdifferentoperatingconditions.

Theelectroniccontrolunit(ECU)continuouslymonitorsthe
operationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the
malfunctionindicatorlight(MIL)isilluminated.TheMILis
theredlightlocatedintherightconsolepanel.

OncetheMILilluminates,initialtroubleshooting
checksshouldbemade.RefertotheMILsectionunder
Toubleshooting.

Ifthesechecksdonotcorrecttheproblem,furtherdiagnosis
andservicingbyanAuthorizedServiceDealerisnecessary.

42

ElectricalSystem

G021395

Maintenance

ServicingtheBattery

ServiceInterval:Monthly

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Firstdisconnectthenegativebatterycable(black)from
thenegative(-)(black)batteryterminal(Figure56).

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa
deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassestoshield
youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

4.Slidetheredterminalbootoffthepositive(red)battery
terminalandremovethepositive(+)(red)batterycable
(Figure56).

5.Removethewingnutsecuringthebatteryclamp
(Figure56).

6.Removetheclamp(Figure56).

7.Removethebattery.

Batteryterminalsormetaltoolscouldshortagainst
metalmachinecomponentscausingsparks.Sparks
cancausethebatterygassestoexplode,resulting
inpersonalinjury.

•Whenremovingorinstallingthebattery,donot
allowthebatteryterminalstotouchanymetal
partsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

WARNING

Incorrectbatterycableroutingcoulddamagethe
machineandcablescausingsparks.Sparkscan
causethebatterygassestoexplode,resultingin
personalinjury.

•AlwaysDisconnectthenegative(black)battery
cablebeforedisconnectingthepositive(red)
cable.

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

Figure56

1.Removethewingnutand
clamp

2.Removethenegative
batterycablebeforethe
positive

3.Removethepositive
batterycable

4.Removethebattery

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts
oppositefromthehydraulictank(Figure56).

2.First,installthepositive(red)batterycabletopositive
(+)batteryterminal.

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

43

4.Securethecableswith2bolts,2washers,and2locknuts

g020464

(Figure56).

5.Slidetheredterminalbootontothepositive(red)
batterypost.

6.Installtheclampandsecureitwiththewingnut(Figure

56).

ServicingtheFuses

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

1.Thefusesarelocatedonrighthandconsolenextto
theseat(Figure58).

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparksand
amesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespeciallyimportantto
preventbatterydamagewhenthetemperatureisbelow
32°F(0°C).

1.Chargebatteryfor10to15minutesat25to30amps
or30minutesat10amps.

2.Whenthebatteryisfullycharged,unplugthecharger
fromtheelectricaloutlet,thendisconnectthecharger
leadsfromthebatteryposts(Figure57).

3.Installthebatteryinthemachineandconnectthe
batterycables,refertoInstallingtheBattery(page43).

Note:Donotrunthemachinewiththebattery
disconnected,electricaldamagemayoccur.

2.Toreplacethefuses,pulloutonthefusetoremoveit.

3.Installanewfuse(Figure58).

Figure58

1.Optionalaccesory-15amp3.PTO-10amp

2.Charge-25amp

4.Main-25amp

1.PositiveBatteryPost

2.NegativeBatteryPost

Figure57

3.Red(+)ChargerLead

4.Black(-)ChargerLead

44

DriveSystem

g021420

2 1

3

4

Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproperoperation
ofretractorandbuckle.Replacebeforeoperatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandtheknobsare
ingoodworkingcondition.Makesuretheknobsarefully
engagedwiththeROPSinthefullyraisedposition.The
upperhoopoftherollbarmayneedtobepushedforwardor
pulledrearwardtogetbothknobsfullyengaged.

Figure59

1.ROPSknob(locked
position)

2.PullROPSknoboutand
rotate90degreesto
changerollbarposition

3.Rollbarintheupright
position

4.Rollbarinthefolded
position

AdjustingtheTracking

1.Disengagetheblade-controlswitch(PTO).

2.Drivetoanopenatarea,movethemotion-control
leverstotheneutrallockedposition.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotion-controlleversallthewayforward
untiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust
theleftstopplaterearwardontheleftT-slotuntilthe
machinetracksstraight(Figure60).

7.Ifittrackstotheleft,loosentheboltsandadjustthe
rightstopplaterearwardontherightT-slotuntilthe
machinetracksstraight(Figure60).

8.Tightenthestopplate(Figure60).

45

g027424

CheckingtheWheelLugNuts

g027425

Checkandtorquethewheellugnutsto122-129N-m(90-95
ft-lb).

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

Checkandensurethatthetorqueoftheslottednutis286to
352N-m(211to260ft-lb).

Note:Donotuseanti-seizeonwheelhub.

Figure60

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat13psi(90kPa).
Uneventirepressurecancauseunevencut.Checkthetires
whentheyarecoldtogetthemostaccuratepressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddonot
requireairpressuremaintenance.

Figure61

Figure62

1.Slottednut

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichevercomes

rst)

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition,
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Removethedustcapfromcasterandtightenthe
locknut(Figure63).

4.Tightenthelocknutuntilthespringwashersareatand
thenbackoffa1/4turntoproperlysetthepre-loadon
thebearings(Figure63).

46

Important:Makesurethespringwashersare
installedcorrectlyasshowninFigure63.

5.Installthedustcap(Figure63).

Figure63

1.Springwashers

2.Locknut

3.Dustcap

UsingtheClutchShim

Whentheclutchbrakehasworntothepointwheretheclutch
nolongerengagesconsistently,theshimcanberemovedto
extendtheclutchlife.

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartstostop,and
removethekey.

2.Engagetheparkingbrakeandallowthemachineto
cooldowncompletely.

3.Usinganaircompressor,blowoutanydebrisfrom
underthebrakepoleandaroundthebrakespacers.

Figure65

4.Checktheconditionofthewireharnessleads,
connectors,andterminals.Cleanorrepairasnecessary.

5.Verifythat12Vispresentattheclutchconnectorwhen
thePTOswitchisengaged.

6.Measurethegapbetweentherotorandarmature.If
thegapisgreaterthan1mm(.04inch),proceedwith
thefollowingsteps:

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

Figure64

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

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

Figure66

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,takehold

ofthetabandremovetheshim(Donotdiscard
theshimuntilproperclutchfunctionhasbeen
conrmed).

47

F.Performthefollowingsafetycheck:

i.Sitontheseatandstarttheengine.

ii.Makesurethebladesdonotengagewith

thePTOswitchintheoffpositionand
theclutchdisengaged.

Iftheclutchdoesnotdisengage,installthe
shimandreferencetheTroubleshooting
section.

Figure67

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake
spacers.

D.Re-torqueeachbolt(M6x1)to13N-m(10ft-lb)

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

E.Usinga0.010inchthickfeelergauge,verifythat

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

iii.EngageanddisengagethePTOswitch10

consecutivetimestoensurethattheclutch
isfunctioningproperly.Iftheclutch
doesnotengageproperly,referencethe
Troubleshootingsection.

1.Feelergauge

1.Feelergauge

Figure68

Figure69

•Ifthegapislessthan0.010inch,theninstall

theshimandreferencetheTroubleshooting
section.

•Ifthegapissufcient,proceedtothesafety

checkinstepF.

48

CoolingSystem

G021395

G021397

Maintenance

CheckandCleantheHydraulic UnitShrouds

ServiceInterval:Beforeeachuseordaily

CleaningtheEngineScreen andEngineOilCooler

ServiceInterval:Beforeeachuseordaily

Removeanybuild-upofgrass,dirt,orotherdebrisfromthe
oilcooler(Figure70).

Figure70

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Raisetheseat.

4.Cleanthedebrisandgrassfromthehydraulicunit
shrouds(Figure71).

5.Lowertheseat.

Beforeeachuseremoveanybuild-upofgrass,dirt,or
otherdebrisfromtheenginescreen.Thiswillhelpensure
adequatecoolingandcorrectenginespeedandwillreduce
thepossibilityofoverheatingandmechanicaldamagetothe
engine.

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every100hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Removethecoolingshroudsandfanhousing.

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installthecoolingshroudsandfanhousing.

Figure71

1.Hydraulicunitshrouds

49

BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurethebrakeisadjustedproperlybefore
adjusting.

Note:Thisproceduremustbefollowedaftertherst100
hoursorwhenabrakecomponenthasbeenremovedor
replaced.

DANGER

Mechanicalorhydraulicjacksmayfailtosupport
machineandcauseaseriousinjury.

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

1.Drivethemachineontoalevelsurface.

2.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andengagetheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop,and
removethekey.

4.Raisethebackofthemachineupandsupportthe
machinewithjackstands.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothereleased
position.RefertoUsingtheDriveWheelRelease

Valves(page29).

Figure72

LeftSideShown

1.L-bracket4.Rearlinkageassembly

2.Linkagestop

3.Gap

9.Disengagetheparkingbrake,thelevershouldbein
thedownposition.

10.Turnthewheelhubbyhandinbothdirectionsrelative
tothecaliper;thewheelhubshouldmovefreely
betweenthecaliper.

11.Ifagapisneededorthewheelhubdoesnotmove
freely:

A.Disengagetheparkingbrake.

B.Disconnectandne-tunetherearlinkage

assembly:

5.Caliper

6.Wheelhub

•Shortenthelinktocreateagap.

•Lengthenthelinktoallowwheelhub

movement.

8.Checktoseeifthereisavisiblegapbetweenthe
L-bracketandthelinkagestop(Figure72).

C.Reconnecttherearlinkageassembly.

12.Engagetheparkingbrakeandcheckthegap.

13.Repeatsteps9through13untilavisiblegapisachieved
andthewheelhubrotatesfreely .

14.Repeatthisprocedureforthebrakeontheopposite
side.

15.Rotatethedrivewheelreleasehandletotheoperating
position.RefertoUsingtheDriveWheelRelease

Valves(page29).

16.Installthereartiresandtorquethelugnuts.Referto

CheckingtheWheelLugNuts(page46)

17.Removethejackstands.

50

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating,blades
slippingwhencuttinggrass,frayedbeltedges,burnmarksand
cracksaresignsofawornmowerbelt.Replacethemower
beltifanyoftheseconditionsareevident.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslippingwhen
cuttinggrass,frayedbeltedges,burnmarksandcracksare
signsofawornmowerbelt.Replacethemowerbeltifanyof
theseconditionsareevident.

1.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Lowerthemowertothe76mm(3inch)heightofcut.

4.Removethebeltcovers(Figure73).

Figure73

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto
removetensionontheidlerspring(Figure74).

6.Removethebeltfromthemowerdeckpulleys.

7.Removethebeltguideonthespringloadedidlerarm
showninFigure74.

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysandthe
clutchpulleyundertheengine(Figure74).

Figure74

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

10.InstallthebeltguideontheidlerarmshowninFigure

74.

11.Usingtheratchetinthesquarehole,installtheidler
spring(Figure74).

Makesurethatthespringendsareseatedintheanchor
grooves.

12.Installthebeltcovers(Figure75).

armfortheratchet

7.Beltguide

51

Figure75

1.Positionthebeltcover3.Ensurethetabisunder
themetalcatch

2.Slidebeltcoverunderthe

sidecatches

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Removethemowerbelt.RefertoReplacingtheMower

Belt(page51).

4.Raisethemachineandsupportitwithjackstands.

5.Usearatchetinthesquareholeintheidlerarmto
removetheidlerspring(Figure76).

6.Unhooktheidlerspringfromtheframe(Figure76).

7.Removethebeltfromthehydraulicunitdrivepulleys
andtheenginepulley.

Figure76

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump
pulley

5.Lefthandhydraulicpump
pulley

8.Installthenewbeltaroundenginepulleyandthe2
drivepulleys.

9.Usingaratchetinthesquareholeintheidlerarm,
installtheidlerspringtotheframe(Figure76).

10.Installthemowerbelt.RefertoReplacingtheMower

Belt(page51).

52

ControlsSystem
Maintenance

AdjustingtheControlHandle Position

Therearetwoheightpositionsforthecontrollevers;highand
low .Removetheboltstoadjusttheheightfortheoperator.

1.DisengagethePTO ,movethemotion-controlleversto
theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Loosentheboltsandangenutsinstalledinthelevers
(Figure77).

4.Aligntheleversfronttorearpositionbybringthe
leverstogethertotheneutralpositionandslidethem
untiltheyarealigned,thentightenthebolts(Figure78).

Figure77

1.Bolt

2.Handle4.Nut

3.Controllever

Figure78

AdjustingtheMotion-Control Linkage

Locatedoneithersideofthefueltank,belowtheseatare
thepumpcontrollinkages.Rotatingthepumplinkagewitha
1/2inchwrenchallowsne-tuningadjustmentssothatthe
machinedoesnotmoveinneutral.Anyadjustmentsshould
bemadeforneutralpositioningonly .

WARNING

Theenginemustberunningandthedrivewheels
mustbeturningsothatthemotion-control
adjustmentcanbeperformed.Contactwithmoving
partsorhotsurfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearofrotating
componentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeck-liftpedal
andremovetheheight-of-cutpin.Lowerthedeckto
theground.

2.Raisetherearofmachineupandsupportitwithjack
stands(orequivalentsupport)justhighenoughto
allowthedrivewheelstoturnfreely .

3.Removetheelectricalconnectionfromtheseatsafety
switch,locatedunderthebottomcushionoftheseat.

Note:Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrosstheterminals
intheconnectorofthemainwiringharness.

5.Starttheengine.

Note:Thebrakemustbeengagedandthe
motion-controlleversmustbeouttostartthe
engine.Theoperatordoesnothavetobeinthe

53

seatbecauseofthejumperwirebeingused.Run

g027428

theengineatfullthrottleandreleasethebrake.

6.Runthemachineatleast5minuteswiththe
motion-controlleversatfullforwardspeedtobringthe
hydraulicoiluptooperatingtemperature.

Note:Themotion-controlleverneedstobeinneutral
whilemakinganynecessaryadjustments.

7.Bringthemotion-controlleversintotheneutral
position.

8.Adjustthepumpcontrolrodlengthsbyrotatingthe
doublenutsontherodintheappropriatedirection
untilthewheelsslightlycreepinreverse(Figure79).

AdjustingtheMotion-Control Damper

Thetopdamper-mountingboltcanbeadjustedtoobtaina
moredesiredmotion-controlleverresistance.SeeFigure80
formountingoptions.

Figure80

Right-handmotioncontrolshown

Figure79

1.Doublenuts

9.Movethemotion-controlleverstothereverseposition,
andwhileapplyingslightpressuretothelever,allow
thereverseindicatorspringstobringtheleversback
toneutral.

Note:Thewheelsmuststopturningorslightlycreep
inreverse.

10.Shutoffthemachine.Removethejumperwirefrom
wireharnessandplugtheconnectorintotheseat
switch.

1.T orquethelocknutto23N-m(17ft-lb).Theboltmust
protrudepasttheendofthelocknutaftertorquing.

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

11.Removethejackstands.

12.Raisethedeckandinstalltheheight-of-cutpin.

13.Checkthatthemachinedoesnotcreepinneutralwith
theparkbrakesdisengaged.

54

AdjustingtheMotion-Control Neutral-LockPivot

Theangednutcanbeadjustedtoobtainamoredesired
motion-controlleverresistancewhenmovingittothe
neutral-lockposition.SeeFigure81foradjustmentoptions.

HydraulicSystem
Maintenance

ServicingtheHydraulic

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenthejamnut.

Figure81

1.Flangednut2.Jamnut

System

HydraulicOilType:Toro
orMobil

Important:Useoilspecied.Otheruidscouldcause
systemdamage.

EachHydraulicSystemOilCapacity:52L(52ounces)

persidewithlterchange

®

115W -50.

®

HYPR-OIL

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulicoil

level.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO ,movethemotion-controlleversto
theneutral-lockedposition,andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

4.Allowtheengineandhydraulicsystemtocoolfor10
minutes.

Note:Theoillevelonthedipstickwillbeincorrectif
theoilischeckedwhenthemachineishot.

™

500hydraulicoil

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofthehydraulic
systemreservoirs(Figure82).

7.Removeonedipstickfromthehydraulicreservoir
(Figure82).

8.Wipethedipstickoffandthreadthedipstickintothe
reservoir.

9.Removethedipstickandlookattheend(Figure82).

Note:Iftheoillevelisattheaddmark,slowlypour
onlyenoughoilintothehydraulicreservoirtoraisethe
leveltothefullorHline.

Important:Donotoverllthehydraulicunits
withoilasdamagemayoccur.Donotrunthe
machinewiththeoilbelowtheaddmark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

55

G015459

H

3

4

ReplacingtheHydraulicFiltersand
HydraulicOil

ServiceInterval:Aftertherst250hours—Changethe

hydraulicltersandhydraulicoilwhen
usinganytypeofoil.

Figure82

Eitherdipstickwillbeusedinthemachine

1.Full3.H—meanshighlevel

2.Add4.Dipsticklocationsunder
seat

Every250hours—Changethehydraulicltersand
hydraulicoilwhenusingMobil
dirtyordustyconditions).

Every500hours—Changethehydraulicltersand
hydraulicoilwhenusingToro
hydraulicoil(moreoftenindirtyordustyconditions).

Toreplacethehydraulicoil,theltersneedtoberemoved.
Replacebothatthesametime;refertoServicingthe

HydraulicSystem(page55)fortheoilspecications.

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutral-lockedposition,
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Raisethemachineandsupportitwithjackstands
(Figure83).

®

1oil(moreoftenin

®

HYPR-OIL

™

500

WARNING

Hydraulicoilescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicoilisinjectedintotheskinit
mustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistype
ofinjury.Gangrenemayresultifthisis
notdone.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicoil.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesurethatallhydraulicoilhosesand
linesareingoodconditionandthatall
hydraulicconnectionsandttingsaretight
beforeapplyingpressuretothehydraulic
system.

Figure83

1.Jackstands

4.Removeboththemowerbeltandthepump-drive
belt;refertoReplacingtheMowerBelt(page51)and

ReplacingtheHydraulicPumpDriveBelt(page52).

Note:Thispreventsoilfromgettingonthebelts.

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

56

G008968

1

2

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethatthemowerdeckisleveledbefore

matchingtheheight-of-cut(HOC).

1.Positionmoweronaatsurface.

2.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

Figure84

Bottomviewofthemachine

1.Filterlocations

6.Applyathincoatofhydraulicoiltotherubbergasket
onthereplacementlter(Figure84).

7.Installthereplacementhydrauliclter.

8.Installthepump-drivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine(Figure

83).

10.Addoiltothehydraulicreservoirandcheckforany
leaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabout2minutesto
purgeairfromthesystem.

13.Stoptheengineandcheckforleaks.

14.Checktheoillevelwhiletheoiliscold.

15.Ifrequired,addoiltothehydraulicreservoir.

2.Hydrauliclter

4.Checktirepressureofthedrivetires.Ifneeded,adjust
to90kPa(13psi)

5.Positionthemowertothe76mm(3inch)height-of-cut
position.

LevelingtheDeck

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper
inationpressurefortiresis90kPa(13psi).Adjust
ifnecessary.

4.Positionthetransportlockinthelatchingposition.

5.Pushthedeckliftpedalallthewayforwardandthe
deckwilllatchatthe14cm(5-1/2inch)transport
position(Figure85).

Note:Donotoverll.

57

1.Deckliftpedal

2.Height-of-cutpin

Figure85

3.Transportlock

10.Ifneeded,loosenthewhizlocknutonthesideofthe
yokeandthejamnutontop.Finetunethescrew
adjusterbyturningittoget7.6mm(3inch)height(see

Figure87).

Toincreasetheheight,turntheadjusterscrew
clockwise;todecrease,turncounterclockwise.

Figure87

1.Whizlocknut3.Jamnut

2.Adjusterscrew4.Y oke

6.Inserttheheightadjustmentpinintothe7.6cm(3
inch)cuttingheightlocation.

7.Releasethetransportlockandallowthedecktolower
tothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthelevel
surfacetothefronttipoftheblade(PostionA).The
measurementshouldread7.6mm(3inches)(Figure

86).

11.Ifthefrontdecklinksdonothaveenoughadjustment
toachieveaccuratecutheight,thesinglepoint
adjustmentcanbeutilizedtogainmoreadjustment.

12.Toadjustthesinglepointsystem,loosenthetwobolts
atthebottomoftheheightofcutplate.RefertoFigure

88.

1.7.6cm(3inches)atAis
correct

2.8.3cm(31/4inches)atB
iscorrect

Figure86

3.Measureherefromthe
bladetiptohardsurface

4.MeasureatAandBon
bothsides

Figure88

1.Boltsatthebottomoftheheight-of-cutplate

13.Ifthedeckistoolow ,tightenthesinglepoint
adjustmentboltbyrotatingitclockwise.Ifthedeckis
toohigh,loosenthesinglepointadjustmentboltby
rotatingitcounterclockwise(Figure89).

58

Note:Loosenortightenthesinglepointadjustment

g017036

boltenoughtomovetheheight-of-cutplatemounting
boltsatleast1/3thelengthoftheavailabletravel
intheirslots.Thiswillregainsomeupanddown
adjustmentoneachofthefourdecklinks.

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseasonbecause
sharpbladescutcleanlywithouttearingorshreddingthegrass
blades.Tearingandshreddingturnsgrassbrownattheedges,
whichslowsgrowthandincreasesthechanceofdisease.

Checkthecutterbladesdailyforsharpness,andforany
wearordamage.Filedownanynicksandsharpenthe
bladesasnecessary.Ifabladeisdamagedorworn,replace
itimmediatelywithagenuineT ororeplacementblade.For
convenientsharpeningandreplacement,youmaywantto
keepextrabladesonhand.

DANGER

Awornordamagedbladecanbreak,andapiece
ofthebladecouldbethrownintotheoperator's
orbystander'sarea,resultinginseriouspersonal
injuryordeath.

Figure89

1.Singlepointadjustmentbolt

14.Tightenthetwoboltsatthebottomoftheheightofcut
plate(Figure88).Torqueto37-45N-m(27-33ft-lb).

Note:Inmostconditions,thebackbladetipshould
beadjusted6.4mm(1/4inch)higherthanthefront.

15.Onbothsidesofthedeck,measurefromthelevel
surfacetothebacktipoftheblade(PostionB).The
measurementshouldread8.3cm(31/4inches)(Figure

86).

16.Finetunethescrewadjusterbyturningittoget8.3
mm(3-1/4inches)height(Figure87).

Toincreasetheheight,turntheadjustmentnut
clockwise;todecrease,turncounterclockwise.

17.Measureuntilallfoursidesarethecorrectheight.
Tightenallthenutsonthedeckliftarmassemblies.

18.Lowerdischargechute.

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

Parkthemachineonalevelsurface,disengagethe
blade-controlswitch(PTO),andsettheparkingbrake.Turn
theignitionkeytoOff.Removethekey .

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

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

2.Inspecttheblades,especiallythecurvedarea(Figure

90).Ifyounoticeanydamage,wear,oraslotforming

inthisarea(Figure90),immediatelyinstallanewblade.

Figure90

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

59

CheckingforBentBlades

RemovingtheBlades

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Rotatethebladesuntiltheendsfaceforwardand
backward(Figure91).

4.Measurefromalevelsurfacetothecuttingedge,
positionA,oftheblades(Figure91).

5.Notethisdimension.

Bladesmustbereplacedifasolidobjectishit,ifthebladeis
outofbalanceorisbent.Toensureoptimumperformance
andcontinuedsafetyconformanceofthemachine,use
genuineT ororeplacementblades.Replacementbladesmade
byothermanufacturersmayresultinnon-conformancewith
safetystandards.

1.Holdthebladeendusingaragorthickly-paddedglove.

2.Removethebladebolt,curvedwasher,andbladefrom
thespindleshaft(Figure92).

Figure91

1.Measureherefromblade
tohardsurface

6.Rotatetheoppositeendsofthebladesforward.

7.Measurefromalevelsurfacetothecuttingedgeofthe
bladesatthesamepositionasinstep5above.

8.Thedifferencebetweenthedimensionsobtainedin
steps5and6mustnotexceed1/8inch(3mm).

9.Ifthisdimensionexceeds3mm(1/8inch),theblade
isbentandmustbereplaced;refertoRemovingthe
BladesandInstallingtheBlades.

2.PositionA

WARNING

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedblade
withanewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

Figure92

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

SharpeningtheBlades

WARNING

Whensharpeningblade,piecesofbladecouldbe
thrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpeningblade.

1.Usealetosharpenthecuttingedgeatbothendsof
theblade(Figure93).Maintaintheoriginalangle.The
bladeretainsitsbalanceifthesameamountofmaterial
isremovedfrombothcuttingedges.

Figure93

1.Sharpenatoriginalangle

60

2.Checkthebalanceofthebladebyputtingitonablade
balancer(Figure94).Ifthebladestaysinahorizontal
position,thebladeisbalancedandcanbeused.Ifthe
bladeisnotbalanced,lesomemetalofftheendof
thesailareaonly(Figure95).Repeatthisprocedure
untilthebladeisbalanced.

Figure94

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure95).

Important:Thecurvedpartoftheblademustbe
pointingupwardtowardtheinsideofthemowerto
ensurepropercutting.

2.Installthespringdiskandbladebolt.Thespringdisk
conemustbeinstalledtowardthebolthead(Figure95).
Torquethebladeboltto115-150N-m(85-110ft-lb).

WARNING

Deckliftarmassemblieshavestoredenergy.
Removingthedeckwithoutreleasingthestored
energycancauseseriousinjuryordeath.

DoNotattempttodisassemblethedeckfromthe
frontframewithoutlockingoutthestoredenergy.

1.Stopengine,waitforallmovingpartstostop,and
removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthedeck
totheground.

3.Placetheheightadjustmentpininthe7.6cm(3inch)
cuttingheightlocation.Thislocksthedeckliftarmsin
thelowestpositionwhenthedeckisremovedandthe
storedenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothesquare
holeinthedeckidler(Figure96).

6.Rotatethedeckidlerclockwiseandremovethemower
belt(Figure96).

Figure95

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeT owardsBoltHead

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,thespring
loadeddeckarmsmustbelockedout.

Figure96

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

armfortheratchet

7.Beltguide

7.Removeandretainthehardwareonbothsidesofthe
deckasshowninFigure97.

61

Figure97

g015594

1

6 2

4

7

3

5

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

8.Raisethedeckstrutsandsecurethemintheup
position.Slidethedeckouttotherightsideofthe
machine.

ReplacingtheGrassDeector

WARNING

Anuncovereddischargeopeningcouldallowthe
lawnmowertothrowobjectsintheoperator'sor
bystander'sdirectionandresultinseriousinjury.
Also,contactwiththebladecouldoccur.

Neveroperatethelawnmowerunlessyouinstalla
coverplate,amulchplate,grassdeectororbagger.

1.Removethelocknut,bolt,spring,andspacerholding
thedeectortothepivotbrackets(Figure98).

2.Removedamagedorworngrassdeector.

Figure98

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

5.Springinstalled

7.J-hookendofspring

3.Placespacerandspringontograssdeector.Placeone
J-endofspringbehinddeckedge.

Note:MakesureoneJ-endofspringisinstalled
behinddeckedgebeforeinstallingtheboltasshown
inFigure98.

4.Installboltandnut.PlaceoneJ-hookendofspring
aroundgrassdeector(Figure98).

Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefullopen
positionandensurethatitrotatesintothefull
downposition.

62

Cleaning

Storage

CleaningtheMowerDeck

ServiceInterval:Beforeeachuseordaily

1.Disengagetheblade-controlswitch(PTO),movethe
motion-controlleverstotheneutrallockedposition
andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforallmoving
partstostopbeforeleavingtheoperatingposition.

3.Raisethemowertothetransportposition.

4.Cleantheundersideofthemowerdeck.

DisposingofWaste

Engineoil,batteries,hydraulicoil,andenginecoolantare
pollutantstotheenvironment.Disposeoftheseaccordingto
yourstateandlocalregulations.

CleaningandStorage

Storageareasshouldbeequippedwithatleastoneapproved
portablereextinguisherhavingaminimumcapacityof8.2
kg(18lb)drychemicalwithaB:Crating.DonotuseCarbon
Tetrachlorideextinguishers(Pyreneetc.).

1.Disengagethepowertakeoff(blade-controlswitch
(PTO),settheparkingbrake,andturntheignitionkey
totheoffposition.Removethekey .

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especiallythe
engineandhydraulicsystem.Cleandirtandchafffrom
theoutsideoftheenginecylinderheadnsandblower
housing.

Important:Youcanwashthemachinewithmild
detergentandwater.Donotpressurewashthe
machine.Avoidexcessiveuseofwater,especially
nearthecontrolpanel,engine,hydraulicpumps,
andmotors.

3.Checkthebrake;refertoBrakeMaintenance(page50).

4.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page36).

5.Greasethemachine;refertoGreasingandLubrication

(page34).

6.Changethecrankcaseoil;refertoServicingtheEngine

Oil(page37).

7.Checkthetirepressure;refertoCheckingtheTire

Pressure(page46).

8.Changethehydrauliclters;refertoReplacingthe

HydraulicFiltersandHydraulicOil(page56).

9.Chargethebattery;refertoServicingtheBattery(page

43).

10.Scrapeanyheavybuildupofgrassanddirtfromthe
undersideofthemower,thenwashthemowerwith
agardenhose.

Note:Runthemachinewiththeblade-controlswitch
(PTO)engagedandtheengineathighidlefor2to
5minutesafterwashing.

11.Checktheconditionoftheblades;refertoInspecting

theBlades(page59).

12.Preparethemachineforstoragewhennon-useoccurs
over30days.Starttheengineandrunituntilitstops.

13.Checkandtightenallbolts,nuts,andscrews.Repairor
replaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageorstoragearea.
Removethekeyfromtheignitionswitchandkeepit
outofreachofchildrenorotherunauthorizedusers.
Coverthemachinetoprotectitandkeepitclean.

63

Troubleshooting

Problem

MalfunctionIndicatorLight(MIL)comes
on.

Thestarterdoesnotcrank.

PossibleCauseCorrectiveAction

1.Theengineistoohot.

2.Faultyvalveinfueltank.2.ContactanAuthorizedServiceDealer.

3.Theaircleanerisdirty .3.Makesurethattheaircleanerand

4.Thebatteryisnotcharged.

5.Theconnectionstosensorselectronic
controlunit(ECU)andfuelinjectors
arenotsecuredproperly.

6.Lowvoltagecomingfromthebattery.

7.Afuseisblown.7.Checkandreplaceanyblownfuses.

1.Theblade-controlswitch(PTO)is
engaged.

2.Theparkingbrakeisnoton.

3.Thedriveleversarenotinneutral-lock
position.

4.Theoperatorisnotseated.

5.Thebatteryisdead.

6.Theelectricalconnectionsare
corrodedorloose.

7.Thefuseisblown.7.Replacethefuse.

8.Therelayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

1.Turnengineoffandletitcool.

precleanerareclean.Replaceif
necessary.

4.Chargeorreplacethebattery.

5.ContactanAuthorizedServiceDealer.

6.Ensureagood12voltbatteryisbeing
usedandisfullycharged.

1.Movetheblade-controlswitch(PTO)
todisengaged.

2.Settheparkingbrake.

3.Ensurethatthedriveleversareinthe
neutral-lockposition.

4.Sitontheseat.

5.Chargethebattery.

6.Checktheelectricalconnectionsfor
goodcontact.

Theenginewillnotstart,startshard,or
failstokeeprunning

Theenginelosespower.

1.Thefueltankisempty .1.Fillthefueltank.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thethrottleandchokearenotinthe
correctposition.

4.Thereisdirtinfuellter.4.Replacethefuellter.

5.Thereisdirt,water,orstalefuelinthe
fuelsystem.

6.Theaircleanerisdirty .

7.Theseatswitchisnotfunctioning
properly.

8.Theelectricalconnectionsare
corroded,looseorfaulty.

9.Therelayorswitchisdefective.9.ContactanAuthorizedServiceDealer.

10.Thesparkplugisfaulty.10.Clean,adjust,orreplacesparkplug.

11.Thesparkplugwireisnotconnected.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty .

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandairpassages
abovetheengineareplugged.

5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

6.Thereisdirtinthefuellter.6.Replacethefuellter.

7.Thereisdirt,water ,orstalefuelisin
thefuelsystem.

3.Besurethatthethrottlecontrolis
midwaybetweenthe“SLOW”and
“FAST”positions.

5.ContactanAuthorizedServiceDealer.

6.Cleanorreplacetheaircleaner
element.

7.Checktheseatswitchindicator.
Replacetheseatifneeded.

8.Checktheelectricalconnectionsfor
goodcontact.Cleantheconnector
terminalsthoroughlywithelectrical
contactcleaner,applydielectric
grease,andreconnect.

11.Checkthesparkplugwireconnection.

2.Cleantheaircleanerelement.

4.Removetheobstructionfromthe
coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

64

Problem

PossibleCauseCorrectiveAction

Theengineoverheats.

Themowerpullsleftorright(withlevers
fullyforward)

Themachinedoesnotdrive.

Thereisabnormalvibration.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandairpassages
abovetheengineareplugged.

1.Thetrackingneedsadjustment1.Adjustthetracking.

2.Thetirepressureindrivetiresisnot
correct.

1.Thebypassvalvesarenotclosed
tight.

2.Thepumpbeltisworn,looseorbroken.

3.Thepumpbeltisoffapulley .3.Changethebelt.

4.Theidlersprintisbrokenormissing.4.Replacethespring.

5.Thehydraulicoillevelislowortoohot.5.Addhydraulicoiltoreservoirsorletit

1.Thecuttingblade(s)is/arebentor
unbalanced.

2.Theblademountingboltisloose.2.Tightentheblademountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Theenginepulley ,idlerpulley,orblade
pulleyisloose.

5.Theenginepulleyisdamaged.

6.Thebladespindleisbent.

7.Themotormountislooseorworn.

3.Removetheobstructionfromthe
coolingnsandairpassages.

2.Adjusttirepressureinthedrivetires.

1.Tightenthebypassvalves.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

Mowingisresultinginunevencutting
height.

Thebladesdonotrotate.

Theclutchwillnotengage.

1.Theblade(s)notsharp.1.Sharpentheblade(s).

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

3.Themowerdeckisnotlevel.

4.Theundersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.

6.Thebladespindlebent.

1.Themowerdeckbeltisworn,loose
orbroken.

2.Themowerdeckbeltisoffpulley.

3.Thepumpdrivebeltisworn,looseor
broken.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Thefuseisblown.1.Replacethefuse.Checkcoil

2.Thereislowvoltagesupplyatthe
clutch.

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead

5.Therotor/armatureairgapistoolarge.

3.Levelthemowerdeckfromside-to-side
andfront-to-rear.

6.ContactanAuthorizedServiceDealer.

1.Installanewdeckbelt.

2.Installthemowerdeckpulleyand
checktheidlerpulley,idlerarm,and
springforcorrectpositionandfunction.

3.Checkthebelttensionorinstallanew
belt.

resistance,batterycharge,charging
system,andwiringconnectionsand
replaceifnecessary .

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

wireorelectricalsystem.Cleanthe
connectorcontacts.

5.Removetheshimorreplacetheclutch.

65

Schematics

G021490

BN

BN

BU

BK

Y

W

T

PK

BN

PK

OR

GN

S R

PK PK

PK

LTGR

GY

GY

PK

V

BN

V

OR

GN

OR

R

PK R BK

T

R

BK

GND

PK

BK

BN

BN

BK PK

BK

GND

15A

F4

GY

R

IBA

W

V

BU

V

V

BK

+

S

-

FUEL SENDER

10A

F3

(BRAKE)

SW6

PKOR R

F2

25A

PTO

CLUTCH

BU

1

2

5

4

7

8

(PTO SWITCH)

SW2

25A

LAMP

F1

(SEAT)

SW7

2

3

5

4

1

K2

(START REL AY)

TVS DIODE

U2

(NEUT_R)

SW5

B+

MAG

ECU

REG

START

AC

STARTER

+-

AC

IGNITION

MODULES

SP ARK PLUGSP ARK PLUG

KOHLER EFI

(NEUT_L)

SW4

12

B+

10

KEY_S

9

KEY_A

4

SEAT

11

BRAKE

2

NEUTRAL

3

PTO

5

FUEL

1

START_REL AY

7

MAGNETO

6

FUEL_SOLENOID

8

GROUND

HOUR METER

2

R A

I

A

4

7

1 3

6

5

A

3

SW1

1

B

B

C

B

8

24 5

(IGNITION)

6

5

1

KEY SW

OPTIONAL

ACCES SORIES

2

S

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BL ACK

BN = BROWN

BU = BL UE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = TAN

V = VIOLET

W = WHITE

LPG Electrical

Diagram

BLACK

BLACK

BLACK

BLACK

GREEN

GREEN

+

ENGINE

GROUND

OIL PRESSURE

SWITCH

ENGINE

LPG FUEL SHUT

OFF SOLENOID

RED

WireDiagram(Rev .A)

66

Notes:

67

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment
(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuanttoanagreement
betweenthem,jointlypromisetotheoriginalpurchasertorepairtheT oroProducts
listedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Mid-SizeWalk-BehindMowers

4

•Engines

GrandStand

4

•Engines

•Frame

®

ZMaster

•Engines

2000SeriesMowers

4

•Frame

®

ZMaster

•Engines

•Frame

ZMaster

•Engines

®

3000SeriesMowers

4

5000SeriesMowers

4

®

Mowers

Kawasaki–3years

2years

Kawasaki–3years

5yearsor1,200hours

3years

Lifetime(originalowneronly)

4yearsor500hours

3years

Lifetime(originalowneronly)

5yearsor1,200hours
3years
Lifetime(originalowneronly)
5yearsor1,200hours

KohlerCommand–2years

KohlerEFI–3years

•Frame

®

ZMaster

•Engines

6000SeriesMowers

4

•Frame

®

ZMaster

•Engines

7000SeriesMowers

4

•Frame

®

ZMaster

•Engines

8000SeriesMowers

4

•Frame

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

2years

Lifetime(originalowneronly)

2yearsor1,200hours

2years

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

1

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

2

Whicheveroccursrst.

3

LifetimeFrameW arranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforpartsand
labor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosion
arenotcovered.

4

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer .

1

1

2

3

2

3

2

3

2

3

2

3

2

3

2

3

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship,
followthisprocedure:

1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir
dealership.T olocateadealerconvenienttoyou,refertotheYellowPagesof
yourtelephonedirectory(lookunder“LawnMowers”)oraccessourwebsite
atwww.Toro.com.Y oumayalsocallthenumberslistedinitem#3tousethe
24-hourT oroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService
Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered
underwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith
theassistanceprovided,contactusat:

RLCCustomerCareDepartment

ToroWarrantyCompany

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

888-865-5676(U.S.Customers)

888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures
describedintheOperator'sManual.Suchroutinemaintenance,whetherperformedby
adealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage
andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot
coverthefollowing:

•Costofregularmaintenanceserviceorparts,suchaslters,fuel,lubricants,oil

changes,sparkplugs,airltersbladesharpeningorwornblades,cable/linkage
adjustments,orbrakeandclutchadjustments

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenalteredormisusedorneglectedandrequires

replacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult

Operator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan

10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro
ServiceDealerusingT oroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect,
incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro
Productscoveredbythiswarranty ,includinganycostorexpenseofproviding
substituteequipmentorserviceduringreasonableperiodsofmalfunctionor
non-usependingcompletionofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse)
andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto
thedurationoftheexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages,
orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions
andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry ,
province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheToroimporter.Ifallother
remediesfail,youmaycontactusatT oroWarrantyCompany .

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.

374-0252RevG