Toro 74936, 74938 Operator's Manual

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Page 1

FormNo.3375-649RevA

g019887

ZMaster

Professional6000

SeriesRidingMower

with60inor72inTURBOFORCE DischargeMower

ModelNo.74936—SerialNo.313000001andUp

ModelNo.74938—SerialNo.313000001andUp

Side

Registeratwww.T oro.com. OriginalInstructions(EN)

*3375-649*A

Page 2

WARNING

Introduction

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002

Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisavailableas anoption.Ifyourequireasparkarrestor,contactyour AuthorizedToroDealer.

GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.

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

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

Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely .

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

Wheneveryouneedservice,genuineToroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready .Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.

WARNING

Removingstandardoriginalequipmentpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.FailuretouseoriginalToro partscouldcauseseriousinjuryordeath.Making unauthorizedchangestotheengine,fuelorventing system,mayviolateEPAandCARBregulations.

Replaceallpartsincluding,butnotlimitedto,tires, belts,blades,andfuelsystemcomponentswith originalT oroparts.

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

Engine Owner's Man ual

issuppliedfor

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contactusatwww.T oro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

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

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.

Contents

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

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

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

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

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

ProductOverview.........................................................12

Controls...............................................................12

Specications........................................................13

Operation....................................................................14

AddingFuel...........................................................14

CheckingtheEngineOilLevel.................................15

BreakingInaNewMachine.....................................15

UsingtheRolloverProtectionSystem(ROPS)............15

ThinkSafetyFirst...................................................16

OperatingtheParkingBrake....................................17

OperatingtheMowerBladeControlSwitch

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

OperatingtheThrottle............................................18

OperatingtheChoke...............................................18

OperatingtheIgnitionSwitch..................................18

UsingtheFuelShut-OffValve..................................19

StartingandStoppingtheEngine..............................19

TheSafetyInterlockSystem.....................................20

DrivingForwardorBackward..................................21

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

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

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

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

PositioningtheFlowBafe......................................25

PositioningtheSeat................................................26

UnlatchingtheSeat.................................................26

UsingtheDriveWheelReleaseValves.......................26

UsingtheSideDischarge.........................................27

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

TransportingMachines............................................28

OperatingTips......................................................29

Maintenance.................................................................30

RecommendedMaintenanceSchedule(s)......................30

Lubrication...............................................................31

GreasingandLubrication........................................31

WheretoGreasetheMower.....................................31

LubricateCasterWheelHubs...................................32

EngineMaintenance..................................................33

ServicingtheAirCleaner.........................................33

ServicingtheEngineOil..........................................34

ServicingtheSparkPlug..........................................37

CheckSparkArrester(ifequipped)............................39

FuelSystemMaintenance...........................................39

ReplacingtheFuelFilter..........................................39

ServicingtheFuelTank...........................................40

ElectricalSystemMaintenance....................................40

ServicingtheBattery...............................................40

ServicingtheFuses.................................................42

DriveSystemMaintenance.........................................43

CheckingtheSeatBelt.............................................43

CheckingtheRolloverProtectionSystem(ROPS)

Knobs...............................................................43

AdjustingtheTracking............................................43

CheckingtheTirePressure......................................44

CheckingtheWheelLugNuts..................................44

CheckingtheWheelHubSlottedNut........................44

AdjustingtheCasterPivotBearing............................45

UsingtheClutchShim............................................45

CoolingSystemMaintenance......................................47

ServicingtheEngineOilCooler...............................47

CleaningtheEngineScreen......................................47

CleaningtheEngineCoolingFinsand

Shrouds.............................................................47

CheckandCleantheHydraulicUnitShrouds..............48

BrakeMaintenance....................................................49

AdjustingtheParkingBrake.....................................49

BeltMaintenance......................................................50

InspectingtheBelts................................................50

ReplacingtheMowerBelt........................................50

ReplacingtheHydraulicPumpDriveBelt...................51

ControlsSystemMaintenance.....................................52

AdjustingtheControlHandlePosition......................52

AdjustingtheMotionControlLinkage......................52

AdjustingtheMotionControlDamper......................53

AdjustingtheMotionControlNeutralLock

Pivot.................................................................53

HydraulicSystemMaintenance....................................54

ServicingtheHydraulicSystem.................................54

MowerDeckMaintenance...........................................56

LevelingtheMowerDeck........................................56

ServicingtheCuttingBlades.....................................58

RemovingtheMowerDeck.....................................60

ReplacingtheGrassDeector..................................61

Cleaning...................................................................62

CleaningUndertheMower......................................62

WasteDisposal.......................................................62

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

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

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

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

Page 4

Safety

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

Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrassor, whenequippedwithagrassbagger,forcatchingcutgrass. Anyuseforpurposesotherthanthesecouldprovedangerous touserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2012.

Training

•ReadtheOperator'sManualandothertrainingmaterial.

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

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtohimselforherself,other peopleorproperty.

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.

•Slowdownwhencrossingroadsandsidewalks.Stop

bladesifnotmowing.

•Beawareofthemowerdischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

Safehandlingoffuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely ammableandthevaporsareexplosive.

Page 5

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethefuelcontainerwherethereisanopen

ame,spark,orpilotlightsuchasonawaterheateror onotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch equipmentwithaportablecontainer,ratherthanfroma fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete. Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

Hauling

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•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.

•Letenginecoolbeforestoringthemachine.

•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.

Page 6

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

Page 7

SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.

68-8340

1-403005

98-5954

103-2076

54-9220

58-6520

1.Grease

105-7798

66-1340

Page 8

109-7232

110-2067

107-2102

107-3969

1.Warning—readtheOperator'sManual.

2.Crushinghazard,mower—engagetheparkingbrake,stop theengine,andremovetheignitionkeybeforeworking underthemower.

1.ReadtheOperator'sManual.

1.Main,25A

2.PTO,10A

110-2068

114-4466

3.Charge,25A

4.Auxiliary,15A

Page 9

1.Greasepulleysandspindles

2.Maintenanceinterval—50hours

116-0205

115-7445

116-0211

116-0090

116-0157

1.Locked2.Unlocked

116-0752

Page 10

116-1654

116-4858

116-1716

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresenceswitch

116-2643

116-3303

116-5944

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery .

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

Page 11

120-5897

1.Choke4.Slow

2.Fast

3.Continuousvariable setting

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

5.Powertake-off(PTO), Bladecontrolswitch

109-7069

Page 12

ProductOverview

g019888

G008951

HourMeter

Thehourmeterrecordsthenumberofhourstheenginehas operated.Itoperateswhentheengineisrunning.Usethese timesforschedulingregularmaintenance(Figure6).

FuelGauge

Thefuelgaugeislocatedwiththehourmeterandthebars lightupwhentheignitionswitchison(Figure6).

Theindicatorlightappearswhenthefuellevelislow (approximatelyonegallonremaininginthefueltank).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheindicatewitha blacktrianglethattheinterlockcomponentisinthecorrect position(Figure6).

Figure4

1.Height-of-cutdecklift pedal

2.Transportlock

3.Parkingbrakelever8.Fuelcap

4.Controls

5.Motioncontrollevers

6.Rollbar

7.Seatbelt

9.Mowerdeck

10.Casterwheel

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure4andFigure5).

Figure5

BatteryIndicatorLight

IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturnedon andwhenthechargeisbelowthecorrectoperatinglevel (Figure6).

Figure6

1.Fuelgauge(bars)4.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

5.Lowfuelindicatorlight

1.PTOSwitch4.Hourmeter/Safety

2.Choke

3.Throttlecontrol6.Fuses

5.Ignitionswitch

interlockdisplay/Fuel gauge

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.Pullthechokeknobup toengageit.

Page 13

BladeControlSwitch(PTO)

Specications

Thebladecontrolswitch(PTO)isusedtoengagetheelectric clutchanddrivethemowerblades.Pulltheswitchupto engagethebladesandrelease.Todisengagetheblades,push thebladecontrolswitch(PTO)downormoveamotion controlleverintotheneutrallockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhasthree positions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(undertheseat)when transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesare availableforusewiththemachinetoenhanceandexpand itscapabilities.ContactyourAuthorizedServiceDealeror Distributororgotowww .T oro.comforalistofallapproved attachmentsandaccessories.

Note:Specicationsanddesignaresubjecttochange withoutnotice.

Width:

60inchDeck72inchDeck

WithoutDeck

DeectorUp61.7inches(156.8

DeectorDown75.7inches(192.2

53.0inches(134.6 cm)

cm)

59.1inches(150.1 cm)

73.6inches(187 cm)

87.6inches(222.4 cm)

Length:

60inchDeck72inchDeck

RollBar-Up

RollBar-Down

83.1inches(211.1 cm)

84.8inches(215.4 cm)

86.1inches(218.7 cm)

87.8inches(223.0 cm)

Height:

RollBar-UpRollBar-Down

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

Weight:

ModelWeight

74936

74938

74960CP1269lb(576kg)

74961CP1349lb(612kg)

1269lb(576kg)

1349lb(612kg)

Page 14

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

AddingFuel

•Forbestresults,useonlyclean,fresh,unleadedgasoline

withanoctaneratingof87orhigher((R+M)/2rating method).

•Oxygenatedfuelwithupto10%ethanolor15%MTBE

byvolumeisacceptable.

•Donotuseethanolblendsofgasoline(suchasE15

orE85)withmorethan10%ethanolbyvolume. Performanceproblemsand/orenginedamagemayresult whichmaynotbecoveredunderwarranty.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor onatruckortrailerbedbecauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.

•Whenpractical,removegas-poweredequipment fromthetruckortrailerandrefueltheequipment withitswheelsontheground.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuelcontainers

overthewinterunlessafuelstabilizerisused.

•Donotaddoiltogasoline.

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipeup anygasolinethatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Fill thefueltanktothebottomofthellerneck. Theemptyspaceinthetankallowsgasolineto expand.Overllingmayresultinfuelleakage ordamagetotheengineoremissionsystem(if equipped).

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystemin placeandinproperworkingcondition.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening .

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachinetoprovide thefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysorless.

Forlongerstorageitisrecommendedthatthefueltank bedrained.

•Eliminatesgum-likevarnishbuildupinthefuelsystem,

whichcauseshardstarting

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountofgasstabilizer/conditionertothe gas.

Note:Afuelstabilizer/conditionerismosteffectivewhen mixedwithfreshgasoline.Tominimizethechanceofvarnish depositsinthefuelsystem,usefuelstabilizeratalltimes.

Page 15

FillingtheFuelTank

G009189

G012429

Note:Donotllthefueltankcompletelyfull.Fillthefuel tanktothebottomofthellerneck.Theemptyspaceinthe tankallowsthegasolinetoexpand.

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefueltankcap.

4.Fillthefueltanktothebottomofthellerneck. Ensurethereisemptyspaceinthetanktoallowthe gasolinetoexpand(

Figure7).

BreakingInaNewMachine

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

UsingtheRolloverProtection System(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraisedlockedpositionandusethe seatbelt.

Ensurethattherearpartoftheseatissecuredwith theseatlatch.

WARNING

Thereisnorolloverprotectionwhentherollbaris inthedownposition.

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbaris inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearancepermits andusetheseatbelt.

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

Important:Lowertherollbaronlywhenabsolutely necessary.

Important:Ensurethattherearpartoftheseatis securedwiththeseatlatch.

1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.

Figure7

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,checktheoil levelintheenginecrankcase;refertoCheckingtheEngine OilLevel.

2.Pullbothknobsoutandrotatethem90°sotheyare notengaged(Figure8).

3.Lowertherollbartothedownposition(Figure8).

Page 16

DANGER

Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Thereisnorolloverprotectionwhentherollbaris down.

Alwayskeeptherollbarinthefullyraisedand lockedpositionandusetheseatbelt.

Readandfollowtherolloverprotectioninstructions andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure8

1.ROPSknob

2.PullROPSknoboutand rotate90degrees

3.Rollbarintheupright position

4.Rollbarinthefolded position

4.Toraisetherollbar,raisetherollbartotheoperate position,rotatetheknobssotheymovepartiallyinto thegrooves(Figure8).

5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins (Figure8).Pushontherollbarandensurethatboth pinsareengaged.

Important:Alwaysusetheseatbeltwiththeroll barinthefullyraisedposition.

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthesafety section.Knowingthisinformationcouldhelpyouor bystandersavoidinjury.

Figure9

1.SafeZone-usethe ZMasterhereonslopes lessthan15degreesor atareas.

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

3.Water

CAUTION

Thismachineproducessoundlevelsinexcessof 85dBAattheoperatorsearandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Page 17

Theuseofprotectiveequipmentforeyes,ears,feetandhead

G009027

G016994

G016995

G008945

G009174

isrecommended.

Figure10

1.Wearsafetyglasses

2.Wearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor leaveitunattended.

SettingtheParkingBrake

OperatingtheMowerBlade ControlSwitch(PTO)

Thebladecontrolswitch(PTO)startsandstopsthemower bladesandanypoweredattachments.

EngagingtheBladeControlSwitch (PTO)

Note:Engagingthebladecontrolswitch(PTO)withthe

throttlepositionathalforlesswillcauseexcessivewearto thedrivebelts.

WARNING

Parkingbrakemaynotholdmachineparkedona slopeandcouldcausepersonalinjuryorproperty damage.

Donotparkonslopesunlesswheelsarechocked orblocked

Figure11

ReleasingtheParkingBrake

Figure13

DisengagingtheBladeControlSwitch (PTO)

Figure14

Figure12

Page 18

OperatingtheThrottle

G008946

G008959

START

RUN

STOP

G008947

ThethrottlecontrolcanbemovedbetweenFastandSlow positions(Figure15).

Alwaysusethefastpositionwhenturningonthemowerdeck withthebladecontrolswitch(PTO).

Figure15

Important:Donotengagestarterformorethan5

secondsatatime.Iftheenginefailstostartallow a15secondcool-downperiodbetweenattempts. Failuretofollowtheseinstructionscanburnout thestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthefuel systemhasbeenwithoutfuelcompletely.

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostarttheengine.

2.Pulluponthechokeknobtoengagethechokebefore usingtheignitionswitch(

3.Pushdownonthechoketodisengagethechokeafter theenginehasstarted(

Figure16).

Figure17

2.Turntheignitionkeytothestoppositiontostopthe engine.

Figure16

1.On2.Off

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition(Figure17). Whentheenginesstarts,releasethekey .

Page 19

UsingtheFuelShut-OffValve

G008948

g017006

START

RUN

STOP

G008947

Thefuelshut-offvalveislocatedundertheseat.Movethe seatforwardtoaccessit.

Closethefuelshut-offvalvefortransport,maintenance,and storage.

Ensurethefuelshut-offvalveisopenwhenstartingthe engine.

Figure18

1.On2.Off

StartingandStoppingthe Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,sitontheseat andfastentheseatbelt.

2.Movethemotioncontrolstoneutrallockedposition.

3.Settheparkingbrake;refertoSettingtheParking Brake.

4.Movethebladecontrolswitch(PTO)totheOff position(Figure19).

5.MovethethrottlelevermidwaybetweentheSlowand Fastpositions.

Figure19

6.TurntheignitionkeytotheStartposition(Figure17). Whentheenginesstarts,releasethekey .

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

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthefuel systemhasbeenwithoutfuelcompletely.

Figure20

1.Off3.Start

2.Run

Page 20

StoppingtheEngine

g017007

G009181

TheSafetyInterlockSystem

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60seconds beforeturningtheignitionswitchoff.

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventtheengine fromstartingunless:

•Theparkingbrakeisengaged.

•Thebladecontrolswitch(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked

position

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthelocked positionwiththeparkingbrakeengagedorifyourisefrom theseatwhenthePTOisengaged.

Figure21

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine,as fuelleakagemayoccur.Settheparkingbrakebefore transporting.Makesuretoremovethekeyasthefuel pumpmayrunandcausethebatterytolosecharge.

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.Whenthe componentisinthecorrectposition,atrianglewilllightup inthecorrespondingsquare.

Figure22

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

Page 21

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethemachine eachtime.Ifthesafetysystemdoesnotoperateasdescribed below,haveanAuthorizedServiceDealerrepairthesafety systemimmediately.

1.Sittingontheseat,engagetheparkingbrakeandmove thebladecontrolswitch(PTO)toon.Trystartingthe engine;theengineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeandmove thebladecontrolswitch(PTO)tooff.Moveeither motioncontrollever(outofneutrallockedposition). Trystartingtheengine;theengineshouldnotcrank. Repeatforothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,movethe bladecontrolswitch(PTO)tooffandmovethemotion controlleverstoneutrallockposition.Nowstartthe engine.Whiletheengineisrunning,releasetheparking brake,engagethebladecontrolswitch(PTO)andrise slightlyfromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,movethe bladecontrolswitch(PTO)tooffandmovethemotion controlleverstoneutrallockposition.Nowstartthe engine.Whiletheengineisrunning,centereither motioncontrolandmove(forwardorreverse);the engineshouldstop.Repeatforothermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmovethe motioncontrolleverstoneutrallockposition.Try startingtheengine;theengineshouldnotcrank.

UsingtheMotionControlLevers

Figure23

1.Motioncontrol lever-neutrallockposition

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

DrivingForwardorBackward

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

CAUTION

Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

DrivingForward

Note:Theenginewillstoprunningifthetractioncontrol

leversaremovedwiththeparkingbrakeengaged.

Tostop,pullthemotioncontrolleverstotheneutralposition.

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotioncontrollevers forward(Figure24).

Page 22

G008952

Figure24

G008953

StoppingtheMachine

Tostopthemachine,movethetractioncontrolleversto neutralandmovetolockedposition,disengagethepower takeoff(bladecontrolswitch(PTO),andturntheignition keytooff.

Settheparkingbrakewhenyouleavethemachine;referto SettingtheParkingBrakeinOperation.Remembertoremove thekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

AdjustingtheHeightofCut

UsingtheTransportLock

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrollevers rearward(

Figure25).

Thetransportlockhastwopositionsandisusedwiththe deckliftpedal.Thereisalockpositionandaunlockposition forthetransportposition.Thetransportlockisusedwiththe deckliftpedal.RefertoFigure26

Figure25

Page 23

AdjustingtheHeight-of-CutPin

G017027

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

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfootand raisethemowerdecktothetransportposition(also the5-1/2inch(140mm)cuttingheightposition)

Figure27).

(

3.Toadjust,rotatethepin90degreesandremovethepin fromtheheight-of-cutbracket(Figure27).

4.Selectaholeintheheight-of-cutbracketcorresponding totheheight-of-cutdesiredand,insertthepin (Figure27).

5.Pushonthedecklift,pullbackonthetransportlock, andslowlylowerthemowerdeck.

Figure26

TransportLockPositions

1.Transportlock3.Unlockposition—doesnot lockthemowerdeckinto transportposition

2.Lockposition—mower

deckwilllockintotransport position

Figure27

1.Deckliftpedal

2.Cutofheightpin

3.Transportlock

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,itisrecommended toadjusttheheightoftheanti-scalprollers.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

Page 24

Figure28

G008961

AdjustingtheFlowBafeCam Locks

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

Themowerdischargeowcanbeadjustedfordifferenttypes ofmowingconditions.Positionthecamlocksandbafeto givethebestqualityofcut.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

5.Bolt

Figure29

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Toadjustthecamlocks,swingtheleveruptoloosen thecamlock(Figure31).

4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow .

5.Swingtheleverbackovertotightenthebafeandcam

Figure31).

locks(

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

Figure30

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

1.Unlocklever

2.Rotatethecamlockto increaseordecrease lockingpressure

Figure31

3.Positionthebafe

4.Locklever

Page 25

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse. Adjustmentswillvarybygrasstype,moisturecontent,and heightofgrass.

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggesteduseforthis positionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthemower.

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheToroSFS

mower.

Figure32

PositionB

Usethispositionwhenbagging.Alwaysalignitwiththe bloweropening.

Figure34

Figure33

PositionC

Thisisthefullopenposition.Thesuggesteduseforthis positionisasfollows.

Page 26

PositioningtheSeat

g019754

g019755

WARNING

Theseatcanmoveforwardandbackward.Positiontheseat whereyouhavethebestcontrolofthemachineandaremost comfortable.

Toadjust,movetheleversidewaystounlockseat(Figure35).

Figure35

UnlatchingtheSeat

Theengineandhydraulicdriveunitscanbecome veryhot.Touchingahotengineorhydraulicdrive unitscancausesevereburns.

Allowtheengineandhydraulicdriveunitstocool completelybeforeaccessingthedrivewheelrelease valves.

Thedrivewheelreleasevalvesarelocatedinthebackofeach hydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefullyhorizontal positionwhenoperatingthemachineorseveredamagetothe hydraulicsystemcanoccur.

1.DisengagethePTO(bladecontrolswitch)andturnthe ignitionkeytooff.Movetheleverstoneutrallocked positionandapplyparkingbrake.Removethekey.

2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthepump enablingthewheelstoturn(Figure37).

3.Disengageparkingbrakebeforepushing.

Figure36

1.Seatlatch2.Seat

UsingtheDriveWheelRelease Valves

WARNING

Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury.

Stoptheengine,removethekey,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.

Figure37

1.Verticaltopushthe machine

4.Rotatethereleasevalvelevershorizontallytorunthe machine(Figure37).

2.Horizontaltorunthe machine

Page 27

UsingtheSideDischarge

LoadingMachines

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(blade controlswitch(PTO)totheoffposition,rotate theignitionkeytooffandremovethekey.

•Makesurethegrassdeectorisinthedown position.

Useextremecautionwhenloadingunitsontrailersortrucks. Onefullwidthrampthatiswideenoughtoextendbeyond thereartiresisrecommendedinsteadofindividualrampsfor eachsideoftheunit(Figure38).Thelowerrearsectionof themachineframeextendsbackbetweentherearwheelsand servesasastopfortippingbackward.Havingafullwidth rampprovidesasurfacefortheframememberstocontactif theunitstartstotipbackward.Ifitisnotpossibletouseone fullwidthramp,useenoughindividualrampstosimulatea fullwidthcontinuousramp.

Therampshouldbelongenoughsothattheanglesdonot exceed15degrees( mowercomponentstogetcaughtastheunitmovesfrom ramptotrailerortruck.Steeperanglesmayalsocausethe unittotipbackward.Ifloadingonornearaslope,position thetrailerortrucksoitisonthedownsideoftheslopeand therampextendsuptheslope.Thiswillminimizetheramp angle.Thetrailerortruckshouldbeaslevelaspossible.

Important:DoNotattempttoturntheunitwhileon theramp;youmaylosecontrolanddriveofftheside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

Figure38).Asteeperanglemaycause

WARNING

Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.

•Useextremecautionwhenoperatingauniton aramp.

•EnsuretheROPSisintheuppositionwhile usingtheseatbeltwhenloadingthemachine. EnsuretheROPSwillclearthetopofan enclosedtrailer.

•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurfacewider thantheunit.

•Donotexceeda15degreeanglebetweenramp andgroundorbetweenrampandtrailerortruck.

•Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

Page 28

Figure38

Figure39

1.Tractionunittiedownloops

1.Trailer3.Notgreaterthan

2.Fullwidthramp4.Fullwidthramp—sideview

15degrees

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthemachine. Ensurethatthetrailerortruckhasallnecessarybrakes, lighting,andmarkingasrequiredbylaw.Pleasecarefullyread allthesafetyinstructions.Knowingthisinformationcould helpyou,yourfamily,petsorbystandersavoidinjury.

WARNING

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

Donotdrivemachineonapublicstreetorroadway .

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicleand connectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.Ensurethe rollbarisinthefullyraisedandlockedpositionanduse theseatbeltwhenloadingandunloading.

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

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

Figure39).

Page 29

OperatingTips

FastThrottleSetting

cuttingheighthigherthanusualandcutthegrassatthis setting.Thencutthegrassagainusingthelower,normal setting.

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

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethecutting heightofthemowerdoesnotscalpanyunevenground. However,thecuttingheightusedinthepastisgenerallythe bestonetouse.Whencuttinggrasslongerthansixinchestall, youmaywanttocutthelawntwicetoensureanacceptable qualityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.Cutting morethanthatisnotrecommendedunlessgrassissparse,or itislatefallwhengrassgrowsmoreslowly.

MowingDirection

WhenStopping

Ifthemachine'sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyourlawn. Toavoidthis,moveontoapreviouslycutareawiththeblades engaged.

KeeptheUndersideoftheMowerClean

Cleanclippingsanddirtfromtheundersideofthemower aftereachuse.Ifgrassanddirtbuildupinsidethemower, cuttingqualitywilleventuallybecomeunsatisfactory.

BladeMaintenance

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

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhichenhances decompositionandfertilization.

MowatCorrectIntervals

Normally,moweveryfourdays.Butremember,grassgrows atdifferentratesatdifferenttimes.Sotomaintainthesame cuttingheight,whichisagoodpractice,mowmoreoftenin earlyspring.Asthegrassgrowthrateslowsinmidsummer, mowlessfrequently .Ifyoucannotmowforanextended period,rstmowatahighcuttingheight;thenmowagain twodayslateratalowerheightsetting.

CuttingSpeed

Toimprovecutquality ,useaslowergroundspeedincertain conditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthemower youpreviouslyused,raisethecuttingheighttoensurethat uneventurfisnotcuttooshort.

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raisethe

Page 30

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

Every50hours

Every100hours

Every150hours

MaintenanceProcedure

•Checkthewheellugnuttorque.

•Checkthewheelhubslottednuttorque.

•Checktheparkbrakeadjustment.

•Changethehydraulicltersandhydraulicoilwhenusinganytypeofoil.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreen.

•Checkandcleanthehydraulicunitshrouds.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

•Lubricatethemowerdeckliftpivots.

•Inspecttheprimarylter.

•Changetheengineoil.Oillterisrecommended.(moreoftenindirtyordusty conditions)

•Replacethefuellter.(moreoftenindirtyordustyconditions).

•Cleantheengineoilcooler.

•Checkandcleanenginecoolingnsandshrouds.

Every200hours

Every250hours

Every300hours

Every500hours

Every600hours

Yearlyorbeforestorage

•Check,cleanandregapthesparkplug.

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

•Replacetheprimaryairlter.(moreoftenindustyorsandyconditions)

•Checktheinnerairlter.

•Changetheengineoillter.

•Checkthewheellugnuttorque.

•Checkthewheelhubslottednuttorque.

•Adjustthecasterpivotbearing.

•Checktheparkbrakeadjustment.

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

•Replacetheinnerairlter.

•Replacethesparkplugs.

Monthly

Yearly

•Checkthebattery.

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

Page 31

CAUTION

G017028

G009029

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy .

GreaseType:No.2generalpurposelithiumbaseor molybdenumbasegrease

HowtoGrease

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

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

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

5.Wipeupanyexcessgrease.

WheretoGreasetheMower

ServiceInterval:Every50hours—Greasethemowerdeck

spindlesandidlerarm.

Yearly—Greasethepumpbeltidlerarm.

Yearly—Greasethefrontcasterpivots(moreoftenin dirtyordustyconditions).

Yearly—Repackthefrontcasterwheelbearings(more oftenindirtyordustyconditions).

Important:Makesurecuttingunitspindlesarefullof greaseweekly .

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

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(

4.Greasethethreespindlebearingsuntilgreasecomes outthelowerseals(Figure41).

Figure41).

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every100hours

Lubricatethedeckliftpivots.

Figure40

Figure41

5.Greasethedrivebeltidlerarm(Figure42).

Page 32

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.

Figure42

6.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.

7.Removethehexplug.Threadagreasezerkintothe hole.

8.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

9.Removethegreasezerkinthehole.Installthehexplug anddustcap(

Figure43).

Figure44

1.Sealguard2.Spacernutwithwrench ats

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

4.Removeoneofthespacernutsfromtheaxleassembly inthecasterwheel.Notethatthreadlockingadhesive hasbeenappliedtolockthespacernutstotheaxle. Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly .

5.Pryoutseals,andinspectbearingsforwearordamage andreplaceifnecessary.

6.Packthebearingswithageneral-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Thesealsmustbereplaced.

8.Iftheaxleassemblyhashadbothspacernutsremoved (orbrokenloose),applyathreadlockingadhesive toonespacernutandthreadontotheaxlewiththe wrenchatsfacingoutward.DoNotthreadspacer nutallofthewayontotheendoftheaxle.Leave approximately1/8inch(3mm)fromtheoutersurface ofthespacernuttotheendoftheaxleinsidethenut.

Figure43

9.Inserttheassemblednutandaxleintothewheelonthe sideofthewheelwiththenewsealandbearing.

10.Withtheopenendofthewheelfacingup,llthearea insidethewheelaroundtheaxlefullofgeneral-purpose grease.

11.Insertthesecondbearingandnewsealintothewheel.

12.Applyathreadlockingadhesivetothe2ndspacernut andthreadontotheaxlewiththewrenchatsfacing outward.

13.Torquethenutto75-80in-lb(8-9N-m),loosen,then re-torqueto20-25in-lb(2-3N-m).Makesureaxle doesnotextendbeyondeithernut.

Page 33

14.Reinstallthesealguardsoverthewheelhubandinsert wheelintocasterfork.Reinstallcasterboltandtighten nutfully.

Important:T opreventsealandbearingdamage,check thebearingadjustmentoften.Spinthecastertire.The tireshouldnotspinfreely(morethan1or2revolutions) orhaveanysideplay .Ifthewheelspinsfreely,adjust torqueonspacernutuntilthereisaslightamountof drag.Reapplythreadlockingadhesive.

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every150hours—Inspecttheprimary

lter.

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

Every300hours—Checktheinnerairlter.

Every600hours—Replacetheinnerairlter.

Note:Checktheltersmorefrequentlyiftheoperating conditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Releasethelatchesontheaircleanerandpulltheair cleanercoverofftheaircleanerbody(Figure45).

4.Cleantheinsideoftheaircleanercoverwith compressedair.

5.Gentlyslidetheprimarylteroutoftheaircleaner body(Figure45).

Note:Avoidknockingthelterintothesideofthe body.

6.Removetheinnerlteronlyifyouintendtoreplaceit.

Important:Neverattempttocleantheinnerlter. Iftheinnerlterisdirty,thentheprimarylteris damaged.Replacebothlters.

7.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutsideof thelter.Holesinthelterwillappearasbrightspots. Ifthelterisdamageddiscardit.

Page 34

Figure45

G016165

g012991

SAE 30

1.Aircleanerbody4.Aircleanerlatch

2.Innerairlter

3.Primaryairlter

5.Aircleanercover

Figure46

ServicingthePrimaryFilter

•Iftheprimarylterisdirty,bent,ordamaged,replaceit.

•Donotcleantheprimarylter.

ServicingtheInnerFilter

Replacetheinnerlter,nevercleanit.

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

InstallingtheFilters

Important:T opreventenginedamage,alwaysoperate

theenginewithbothairltersandcoverinstalled.

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

2.Iftheinnerlterisbeingreplaced,carefullyslideitinto thelterbody(Figure45).

3.Carefullyslidetheprimarylterovertheinnerlter (Figure45).

1.Aircleanercover3.Breathevalve.

2.Throttlemechanism

5.Securethecoverwiththelatches(Figure45).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceclassSJorhigher)

OilCapacity:withalterchange,99ounces(2.9L)

Viscosity:Seethetablebelow .

Note:Ensurethattheprimarylterisfullyseatedby pushingonitsouterrimwhileinstallingit.

Figure47

Important:Donotpressonthesoftinsidearea

ofthelter.

4.Positiontheaircleanercoversothatthebreather valvedoesnotinterferewiththethrottlemechanism (

Figure46).

Note:Useofsyntheticoilhaving5W-20or5W -30ratingis acceptable,upto4degreesC(40degreesF).

Note:Syntheticoilswillprovidebetterstartinginextreme coldbelow-23degreesC(-10degreesF).

Page 35

CheckingtheEngineOilLevel

G008804

G008792

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donotrun enginewithoilbelowthelowmarkbecausetheengine maybedamaged.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure48).

Figure48

Page 36

ChangingtheEngineOil

G008804

G008793

G008796

ServiceInterval:Every150hours(moreoftenindirtyor

dustyconditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunveminutes.Thiswarms theoilsoitdrainsbetter.

2.Parkthemachinesothattherearisslightlylowerthan thefronttoensuretheoildrainscompletely .

3.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure49).

5.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloilto bringittotheFullmark(Figure50).

Figure50

6.Starttheengineanddrivetoaatarea.Checktheoil levelagain.

ChangingtheEngineOilFilter

ServiceInterval:Every300hours

Note:Changetheengineoilltermorefrequentlywhen operatingconditionsareextremelydustyorsandy.

1.Cleantheareaaroundtheoillter.

2.Draintheoilfromtheengine;refertoChangingthe EngineOil.

3.Changetheengineoillter(

Figure51).

Figure49

Page 37

G015196

G015198

3/4

ServicingtheSparkPlug

ServiceInterval:Every200hours—Check,cleanandregap

thesparkplug.

Every600hours—Replacethesparkplugs.

Makesuretheairgapbetweenthecenterandsideelectrodes iscorrectbeforeinstallingthesparkplug.Useasparkplug wrenchforremovingandinstallingthesparkplug(s)anda gappingtool/feelergaugetocheckandadjusttheairgap. Installanewsparkplug(s)ifnecessary.

Type:Champion

AirGap:0.030inch(0.76mm)

XC10YCorequivalent

RemovingtheSparkPlug

1.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

2.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

3.Removethelefthandhydraulicunitshroudintheorder listedwith sparkplug.

Figure52.Thisgivesyouaccesstothefront

Figure51

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

4.Fillthecrankcasewiththepropertypeofnewoil;refer toChangingtheOil.

Page 38

G008803

CheckingtheSparkPlug

G008794

G015200

Important:Replacethesparkplug(s)whenithas:a blackcoating,wornelectrodes,anoilylm,cracksor reuseisquestionable.

Ifyouseelightbrownorgrayontheinsulator,theengineis operatingproperly.Ablackcoatingontheinsulatorusually meanstheaircleanerisdirty.

Setthegapto0.030inches(0.76mm).

Figure54

InstallingtheSparkPlug

Figure52

1.Pullthistabouttothe sideinthedirectionofthe arrow

2.Pulltheshroudoffofthis frametabinthedirection ofthearrow

4.Removethesparkplug.

Tightenthesparkplug(s)to18-22ft.-lb(24.4–29.8N-m).

3.Pulltheshroudoffofthis frametabinthedirection ofthearrow

4.Shroud

Figure55

Figure53

5.Installthelefthandhydraulicunitshroud(Figure52).

Page 39

CheckSparkArrester(if

G008963

12

equipped)

ServiceInterval:Every50hours

FuelSystem Maintenance

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresultin personalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacethearrester.

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

ReplacingtheFuelFilter

ServiceInterval:Every150hours/Yearly(whichevercomes

rst)(moreoftenindirtyordusty conditions).

Thefuellterislocatedneartheengineonthefrontorrear sideoftheengine.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Allowthemachinetocooldown.

4.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

5.Closethefuelshutoffvalveundertheseat(

Figure56).

Figure56

1.Fuellter

2.Hoseclamp

6.Squeezetheendsofthehoseclampstogetherandslide

themawayfromthelter(Figure56).

7.Removethelterfromthefuellines.

8.Installanewlterandmovethehoseclampscloseto thelter(Figure56).

9.Openthefuelshutoffvalve.

Note:Itisimportanttoreinstallthefuellinehosesand securewithplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineawayfrom componentsthatcouldcausefuellinedamage.

3.Fuelline

Page 40

ServicingtheFuelTank

ElectricalSystem

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankandservices anycomponentsofthefuelsystem.

Maintenance

ServicingtheBattery

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.

•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

Page 41

WARNING

G008804

g014731

Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.

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

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

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

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

4.Slidetheredterminalbootoffthepositive(red)battery terminalandremovethepositive(+)(red)batterycable (Figure57).

5.Removethewingnutssecuringthebatteryclamp (Figure57).

6.Removetheclamp(Figure57).

7.Removethebattery.

Figure57).

1.Removethewingnutsand clamp

2.Removethenegative batterycablebeforethe positive

Figure57

3.Removethepositive batterycable

4.Removebattery

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure57).

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

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

4.Securethecableswith2bolts,2washers,and2locknuts

Figure57).

(

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.Installtheclampandsecureitwiththewingnut (Figure57).

Page 42

ChargingtheBattery

ServicingtheFuses

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(Figure58).

3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

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

1.Thefusesarelocatedonrighthandconsolenextto theseat(

Figure59).

2.Toreplacethefuses,pulloutonthefusetoremoveit.

3.Installanewfuse(Figure59).

1.PositiveBatteryPost

2.NegativeBatteryPost

Figure58

3.Red(+)ChargerLead

4.Black(-)ChargerLead

Figure59

1.Optionalaccesory-15amp

2.Charge-25amp5.Console

3.PTO-10amp

4.Main-25amp

Page 43

DriveSystem Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproperoperation ofretractorandbuckle.Replacebeforeoperatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandtheknobsare ingoodworkingcondition.Makesuretheknobsarefully engagedwiththeROPSinthefullyraisedposition.The upperhoopoftherollbarmayneedtobepushedforwardor pulledrearwardtogetbothknobsfullyengaged.

Figure60

1.ROPSknob(locked position)

2.PullROPSknoboutand rotate90degreesto changerollbarposition

3.Rollbarintheupright position

4.Rollbarinthefolded position

AdjustingtheTracking

1.Disengagethebladecontrolswitch(PTO).

2.Drivetoanopenatarea,movethemotioncontrol leverstotheneutrallockedposition.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotioncontrolleversallthewayforward untiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust theleftstopplaterearwardontheleftT-slotuntilthe machinetracksstraight(Figure61).

7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplaterearwardontherightT-slotuntilthe machinetracksstraight(Figure61).

8.Tightenthestopplate(Figure61).

Page 44

g019756

Figure61

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

CheckingtheWheelLugNuts

Checkandtorquethewheellugnutsto90-95ft-lb(122-129 N-m).

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

SeeFigure63todeterminewhichslottednuthasbeen installedontheunit.

Figure63

1.StyleA(blacknish)3.StyleB(yellowzinc)

2..03inch(.76mm)4..24inch(6mm)

•StyleA(blacknish):

Torquetheslottednutto211-260ft-lb(286-352N-m).

Note:DoNotuseanti-seizeonwheelhub.

•StyleB(yellowzinc):

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat13psi(90kPa). Uneventirepressurecancauseunevencut.Checkthetires whentheyarecoldtogetthemostaccuratepressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddonot requireairpressuremaintenance.

Figure62

1.Removeanddiscardthecotterpin.

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

3.Checkdistancefrombottomofslotinnuttoinside edgeofhole.Twothreads(0.1inch)orlessshould beshowing.

Figure64

1.0.1inchmax2.Nomorethantwothreads (0.1inchmax)shouldbe showinghere.

4.Ifmorethantwothreads(0.1inch)areshowing removenutandinstallwasherbetweenhuband nut.

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

Page 45

6.Thentightennutuntilthenextsetofslotslineup withthecrossholeinshaft.Donotloosennutto aligntheslot.Ifrequired,tightentothenextset ofslots.

7.Installanewcotterpin.

Note:DoNotuseanti-seizeonwheelhub.

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichevercomes

rst)

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwithclutchesthat containabrakeshim.Whentheclutchbrakehasworntothe pointwheretheclutchnolongerengagesconsistently ,the shimcanberemovedtoextendtheclutchlife.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removethedustcapfromcasterandtightenlocknut

Figure65).

(

4.Tightenthelocknutuntilthespringwashersareatand thenbackoffa1/4turntoproperlysetthepre-loadon thebearings(Figure65).

Important:Makesurethespringwashersare installedcorrectlyasshowninFigure65.

5.Installthedustcap(Figure65).

Figure66

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.Allow themachinetocoolcompletelybeforestartingthese instructions.

2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.

Figure65

1.SpringWashers3.DustCap

2.LockNut

Figure67

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairasnecessary.

4.Verifythat12Vispresentattheclutchconnectorwhen thePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature.If thegapisgreaterthan.04inch(1mm),proceedwith thefollowingsteps:

Page 46

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

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

Figure68

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,takehold

ofthetabandremovetheshim(DoNotdiscard theshimuntilproperclutchfunctionhasbeen conrmed).

Figure70

1.Feelergauge

Figure71

1.Feelergauge

•Ifthegapislessthan0.010inch,thenreinstall

theshimandreferencetheTroubleshooting section.

Figure69

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake spacers.

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

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

E.Usinga0.010inchthickfeelergauge,verifythat

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

•Ifthegapissufcient,proceedtothesafety

checkinstepF.

F.Performthefollowingsafetycheck:

i.Sitontheseatandstarttheengine.

ii.MakesurethebladesDoNotengage

withthePTOswitch“off”andtheclutch disengaged.

Iftheclutchdoesnotdisengage, reinstalltheshimandreferencethe Troubleshootingsection.

iii.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly .Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

Page 47

CoolingSystem

G015199

2 1

G016905

2 1

CleaningtheEngineScreen

Maintenance

ServicingtheEngineOil Cooler

ServiceInterval:Every150hours

1.Toaccessandservicetheoilcooler,removethetop mountingscrewandloosenthetwosidescrews.

2.Removetheshroud.

3.Cleantheengineoilcoolerwithcompressedair (Figure72).

4.Installtheshroudandinstallthescrews.

ServiceInterval:Beforeeachuseordaily

Beforeeachuseremoveanybuild-upofgrass,dirtor otherdebrisfromtheenginescreen.Thiswillhelpinsure adequatecoolingandcorrectenginespeedandwillreduce thepossibilityofoverheatingandmechanicaldamagetothe engine.

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every150hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removetherighthandshroudbyremovingthetop mountingscrewandloosenthetwosidescrews

Figure73).

(

1.Shroudscrews

2.Shroud

Figure72

3.Engineoilcooler

Figure73

Righthandsideshown

1.Shroudscrews

4.Removethetopmountingscrewandloosenthetwo sidescrewsonthelefthandshroud(

5.Pullupandremovethelefthandshroud,feedingitout aroundthefuelpumpandbracket.

6.Removethetwoscrewsontheleftandrighthandsides inthecoolingfanhousingasshowninFigure74.

2.Righthandshroud

Figure73).

Page 48

g016907

Figure74

1.Oillter

2.Leftsideboltsforcooling fanhousing

3.Battery

4.Rightsideboltsforcooling fanhousing

7.Removethecoolingfanhousing.

8.Usingcompressedair,blowoutanydebrisandgrass fromtheengineparts,particularlyaroundthecylinder headcoolingnsandignitioncoils.

9.Installalltheshroudsontotheengine.

CheckandCleantheHydraulic UnitShrouds

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisetheseat.

4.Cleanthedebrisandgrassfromthehydraulicunit shrouds(Figure75).

Figure75

1.Hydraulicunitshrouds

5.Lowertheseat.

Page 49

BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly.Thisprocedure mustbefollowedaftertherst100hoursorwhenabrake componenthasbeenremovedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop,and removethekey .

Figure76

LeftHandBrakeShown

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

DANGER

Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury.

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothereleased position.RefertotheUsingtheDriveWheel ReleaseV alvessectioninOperation.

8.Measuretheoveralllengthofthecompressionspring. Thecorrectlengthshouldbebetween1-1/2and 1-9/16inches(3.8and4.0cm).Ifthespringlengthis withinthisrange,noadjustmentisneeded.Ifitisnot, proceedtostep9.

9.Holdthethreadedrodendwithatoolandadjust thelocknutuntilthespringlengthisbetween1-1/2 and1-9/16inches(3.8and4.0cm)(Figure76).Do Notallowthecabletoturnwhenthenutsarebeing loosened.

1.Cableanchor5.Caliper

2.Holdthreadedrodhere

3.Measure7.Threadedrod

4.Locknut8.Hub

10.Disengagetheparkbrake.Turnthewheelhubbyhand inbothdirectionsrelativetothecaliper;nodragofthe caliperpadonthewheelhubisdesired.

11.Ifthereisnomovementbetweenthehubandthe caliperthenrepeattheadjustment(drivereleasevalves mustbeinthereleasedpositiononthehydros).

12.Afteradjustingthebrakesonbothsidesofthemower, cyclethebrakehandleaminimumofsixtimestoallow thecabletoseatintothesheathandmountingtabs.

13.Recheckthespringlength;engagetheparkbrakeand repeatsteps8through11ifthelengthisnotinthe correctrange.

14.Rotatethedrivewheelreleasehandletotheoperating position.RefertotheUsingtheDriveWheel ReleaseV alvessectioninOperation.

15.Installthereartiresandtorquelugnutsbetween90and 95ft-lb(122and129N-m).

16.Removejackstands.

6.Compressionspring

Page 50

BeltMaintenance

G009036

InspectingtheBelts

ServiceInterval:Every50hours

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

ReplacingtheMowerBelt

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

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Lowerthemowertothe3inch(76mm)heightofcut.

4.Removethebeltcovers(Figure77).

Figure77

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(Figure78).

6.Removethebeltfromthemowerdeckpulleys.

7.Removethebeltguideonthespringloadedidlerarm showninFigure78.

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysandthe clutchpulleyundertheengine(Figure78).

Figure78

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

10.Installthebeltguideontheidlerarmshownin Figure78.

11.Usingtheratchetinthesquarehole,installtheidler spring(Figure78).

Makesurethespringendsareseatedintheanchor grooves.

12.Installthebeltcovers(

armfortheratchet

7.Beltguide

Figure79).

Page 51

Figure79

1.Positionthebeltcover3.Ensurethetabisunder

2.Slidebeltcoverunderthe sidecatches

themetalcatch

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.

4.Raisethemachineandsupportitwithjackstands

Figure80).

(

Figure80

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump pulley

5.Lefthandhydraulicpump pulley

5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure80).

6.Unhooktheidlerspringfromtheframe(Figure80).

7.Removethebeltfromthehydraulicunitdrivepulleys andtheenginepulley

8.Installthenewbeltaroundenginepulleyandthetwo drivepulleys.

9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(Figure80).

10.Installthemowerbelt.RefertoReplacingtheMower Belt.

Page 52

ControlsSystem Maintenance

AdjustingtheControlHandle Position

Therearetwoheightpositionsforthecontrollevers;highand low .Removetheboltstoadjusttheheightfortheoperator.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Loosentheboltsandangenutsinstalledinthelevers (Figure81).

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslidethem untiltheyarealigned,thentightenthebolts(Figure82).

Figure81

1.Bolt

2.Handle4.Nut

3.Controllever

Figure82

AdjustingtheMotionControl Linkage

Locatedoneithersideofthefueltank,belowtheseatare thepumpcontrollinkages.Rotatingthepumplinkagewitha 1/2inchwrenchallowsnetuningadjustmentssothatthe machinedoesnotmoveinneutral.Anyadjustmentsshould bemadeforneutralpositioningonly .

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearofrotating componentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdecktothe ground.

2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseatsafety switch,locatedunderthebottomcushionoftheseat. Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrosstheterminals intheconnectorofthemainwiringharness.

5.Startengine.Brakemustbeengagedandmotion

controlleversouttostartengine.Operatordoes nothavetobeintheseatbecauseofthejumper wirebeingused.Runengineatfullthrottleand

releasebrake.

Page 53

6.Runtheunitatleast5minuteswiththedriveleversat

g019757

fullforwardspeedtobringhydraulicoiluptooperating temperature.

Note:Themotioncontrolleverneedstobeinneutral whilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsbyrotating thedoublenutsontherodintheappropriatedirection untilthewheelsslightlycreepinreverse(Figure83). Movethemotioncontrolleverstothereverseposition andwhileapplyingslightpressuretotheleverallow thereverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningorslightly creepinreverse.

Figure84

RHMotionControlShown

1.T orquethelocknutto200in-lb(16.7ft-lb).Boltmust protrudepastendoflocknutaftertorque.

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

Figure83

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwireharness andplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutralwith theparkbrakesdisengaged.

AdjustingtheMotionControl NeutralLockPivot

Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittotheneutral lockposition.SeeFigure85foradjustmentoptions.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

AdjustingtheMotionControl Damper

Thetopdampermountingboltcanbeadjustedtoobtain amoredesiredmotioncontrolleverresistance.See Figure84formountingoptions.

Figure85

1.Flangednut2.Jamnut

Page 54

HydraulicSystem

G015459

Maintenance

ServicingtheHydraulic System

HydraulicOilType:Toro orMobil

Important:Useoilspecied.Otheruidscouldcause systemdamage.

EachHydraulicSystemOilCapacity:52ounces(1.5l)per

sidewithlterchange

115W-50.

HYPR-OIL

™

500hydraulicoil

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulicoil

level.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

3.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

4.Allowtheengineandhydraulicsystemtocoolforten minutes.

Note:Theoillevelonthedipstickwillbeincorrect whentheoilischeckedandtheunitishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofhydraulicsystem reservoirs(Figure86).

Figure86

Eitherdipstickwillbeusedinthemachine

1.Full3.H–meanshighlevel

2.Add4.Dipsticklocationsunder seat

WARNING

Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury.

7.Removeonedipstickfromthehydraulicreservoir Figure86).

(

8.Wipethedipstickoffandthreadthedipstickintothe

reservoir.

9.Removethedipstickandlookattheend(Figure86).

Iftheoillevelisattheaddmark,slowlypouronly enoughoilintothehydraulicreservoirtoraisethelevel tothefullorHline.

Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewiththeoilbelowtheaddmark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

•Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistype ofinjury.Gangrenemayresultifthisis notdone.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

Page 55

ReplacingtheHydraulicFiltersand

G008968

HydraulicOil

ServiceInterval:Aftertherst250hours—Changethe

hydraulicltersandhydraulicoilwhen usinganytypeofoil.

Every250hours—Changethehydraulicltersand hydraulicoilwhenusingMobil

1oil(moreoftenin

dirtyordustyconditions).

Every500hours—Changethehydraulicltersand hydraulicoilwhenusingToro

HYPR-OIL

™

hydraulicoil(moreoftenindirtyordustyconditions).

Toreplacethehydraulicoil,theltersneedtoberemoved. Replacebothatthesametime.Refertotheoilspecications underServicingtheHydraulicSystemforthecorrectoil.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisethemachineandsupportitwithjackstands

Figure87).

(

500

Figure88

BottomViewofMachine

1.Filterlocations

2.Hydrauliclter

6.Applyathincoatofhydraulicoiltotherubbergasket onthereplacementlter(Figure88).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

Figure87

1.Jackstands

4.Removeboththemowerbeltandthepumpdrivebelt. Thiswillpreventoilgettingonthebelts.RefertoBelts intheMaintenanceSection.

5.Placeadrainpanunderthelter,removetheoldlter andwipethesurfaceclean(

Figure88).

9.Removethejackstandsandlowerthemachine (Figure87).

10.Addoiltothehydraulicreservoirandcheckforany leaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwominutesto purgeairfromthesystem.Stoptheengineandcheck forleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Donot overll.

Page 56

MowerDeck

G017027

Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethemowerdeckisleveledbeforematchingthe

height-of-cut(HOC).

1.Positionmoweronaatsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

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

5.Positionthemowertothe3inch(76mm)height-of-cut position.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

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

4.Positionthetransportlockinthelatchingposition.

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

Figure89).

Figure89

1.Deckliftpedal

2.Heightofcutpin

6.Inserttheheightadjustmentpinintothe3inch(7.6 cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedecktolower tothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA). Themeasurementshouldread3inches(7.6mm) (Figure90).

3.Transportlock

Figure90

1.3inches(7.6cm)atAis correct

2.31/4inches(8.3cm)atB iscorrect

3.Measureherefromthe bladetiptohardsurface

4.MeasureatAandBon bothsides

Page 57

10.Fine-tunetheadjustmentnutonthefrontdecklift

G012430

2 1

3 4

g017029

g017036

assemblybyturningit(Figure91).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

Figure92

1.Boltsatthebottomoftheheight-of-cutplate

Figure91

1.Adjustmentnut3.Reardeckadjustment

2.JamNut4.Frontdeckadjustment

11.Ifthefrontdecklinksdonothaveenoughadjustment toachieveaccuratecutheight,thesinglepoint adjustmentcanbeutilizedtogainmoreadjustment.

12.Toadjustthesinglepointsystem,loosenthetwobolts atthebottomoftheheightofcutplate.Referto Figure92.

13.Ifthedeckistoolow ,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.Ifthedeckis toohigh,loosenthesinglepointadjustmentboltby rotatingitcounterclockwise(Figure93).

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

1.Singlepointadjustmentbolt

Figure93

14.Tightenthetwoboltsatthebottomoftheheightofcut plate(Figure92).Torqueto27-33ft-lb(37-45N-m).

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

Page 58

15.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(PostionB). Themeasurementshouldread31/4inches(8.3cm) (Figure90).

16.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(Figure91).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

17.Measureuntilallfoursidesarethecorrectheight. Tightenallthejamnutsonthedeckliftarmassemblies.

18.Lowerdischargechute.

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.

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

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

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges( arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea (Figure94).Ifyounoticeanydamage,wear,oraslot forminginthisarea(Figure94),immediatelyinstalla newblade.

Figure94).Iftheedges

Figure94

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

Page 59

CheckingforBentBlades

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure95).Measurefromalevelsurfaceto thecuttingedge,positionA,oftheblades(Figure95). Notethisdimension.

byothermanufacturersmayresultinnon-conformancewith safetystandards.

1.Holdthebladeendusingaragorthickly-paddedglove.

2.Removethebladebolt,curvedwasher,andbladefrom thespindleshaft(Figure96).

Figure95

1.Measureherefromblade tohardsurface

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).Ifthis dimensionexceeds1/8inch(3mm),thebladeisbent andmustbereplaced;refertoRemovingtheBlades andInstallingtheBlades.

2.PositionA

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedblade withanewblade.

Figure96

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

SharpeningtheBlades

WARNING

Whensharpeningblade,piecesofbladecouldbe thrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpeningblade.

1.Usealetosharpenthecuttingedgeatbothendsof theblade(Figure97).Maintaintheoriginalangle.The bladeretainsitsbalanceifthesameamountofmaterial isremovedfrombothcuttingedges.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthebladeis outofbalanceorisbent.Toensureoptimumperformance andcontinuedsafetyconformanceofthemachine,use genuineTororeplacementblades.Replacementbladesmade

Figure97

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitonablade balancer( position,thebladeisbalancedandcanbeused.Ifthe bladeisnotbalanced,lesomemetalofftheendof

Figure98).Ifthebladestaysinahorizontal

Page 60

thesailareaonly(Figure99).Repeatthisprocedure untilthebladeisbalanced.

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,thespring loadeddeckarmsmustbelockedout.

WARNING

Figure98

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure99).

Important:Thecurvedpartoftheblademustbe pointingupwardtowardtheinsideofthemowerto ensurepropercutting.

2.Installthespringdiskandbladebolt.Thespringdisk conemustbeinstalledtowardthebolthead(Figure99). Torquethebladeboltto85-110ft-lb(115-150N-m).

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.

DoNotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthedeck totheground.

3.Placetheheightadjustmentpininthe3inch(7.6cm) cuttingheightlocation.Thislocksthedeckliftarmsin thelowestpositionwhenthedeckisremovedandthe storedenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothesquare holeinthedeckidler(

6.Rotatethedeckidlerclockwiseandremovethemower belt(Figure100).

Figure100).

1.SailAreaofBlade

2.Blade

3.SpringDisk

Figure99

4.BladeBolt

5.ConeT owardsBoltHead

Page 61

Figure101

Figure100

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

armfortheratchet

7.Beltguide

7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure101.

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,springandspacerholdingthe deectortothepivotbrackets(Figure102).Remove damagedorworngrassdeector.

Page 62

g015594

6 2

Figure102

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisethemowertothetransportposition.

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring

2.Placespacerandspringontograssdeector.Placeone Jendofspringbehinddeckedge.

Note:MakesureoneJendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshownin Figure102.

3.Installboltandnut.PlaceoneJhookendofspring aroundgrassdeector(Figure102).

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

5.Springinstalled

7.Jhookendofspring

WasteDisposal

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

Page 63

Storage

CleaningandStorage

1.Disengagethepowertakeoff(bladecontrolswitch (PTO),settheparkingbrake,andturntheignitionkey toOff.Removethekey.

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

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

3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.

4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.

5.Greasethemachine;refertoGreasingandLubrication intheMaintenanceSection.

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankinthe MaintenanceSection.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly .Recycleasperlocal

codes.

Important:Donotstore stabilizer/conditionedfuelover90days.

13.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageorstoragearea. Removethekeyfromtheignitionswitchandkeepit outofreachofchildrenorotherunauthorizedusers. Coverthemachinetoprotectitandkeepitclean.

6.Changethecrankcaseoil;refertoServicingtheEngine OilintheMaintenanceSection.

7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.

8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.

9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.

10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:Runthemachinewiththebladecontrolswitch (PTO)engagedandtheengineathighidlefor2to 5minutesafterwashing.

11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.

12.Preparethemachineforstoragewhennon-useoccurs over30days.Preparethemachineforstorageas follows:

A.Addapetroleumbasedstabilizer/conditionerto

fuelinthetank.Followmixinginstructionsfrom thestabilizermanufacturer.Donotuseanalcohol basedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandusedat alltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

Page 64

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails tokeeprunning

PossibleCauseCorrectiveAction

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

2.Parkingbrakeisnoton.

3.Driveleversarenotinneutrallock position.

4.Operatorisnotseated.4.Sitontheseat.

5.Batteryisdead.

6.Electricalconnectionsarecorrodedor loose.

7.Fuseisblown.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer .

1.Fueltankisempty.

2.Fuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow.

4.Thethrottleandchokearenotinthe correctposition.

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

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly.8.Checktheseatswitchindicator.

9.Electricalconnectionsarecorroded, looseorfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.12.Checkthesparkplugwireconnection.

disengaged.

2.Settheparkingbrake.

3.Ensurethedriveleversareinthe neutrallockposition.

5.Chargethebattery .

6.Checktheelectricalconnectionsfor goodcontact.

7.Replacefuse.

1.Fillthefueltank.

3.Addoiltothecrankcase.

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

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleaner element.

Replaceseatifneeded.

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

11.Clean,adjustorreplacesparkplug.

Enginelosespower.

Engineoverheats.

Mowerpullsleftorright(withleversfully forward)

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesabove theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

7.Dirt,water,orstalefuelisinthefuel system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesabove theengineareplugged.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

Page 65

Problem

PossibleCauseCorrectiveAction

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Bypassvalvesisnotclosedtight.1.Tightenthebypassvalves.

2.Pumpbeltisworn,looseorbroken.

3.Pumpbeltisoffapulley .3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicoillevelislowortoohot.5.Addhydraulicoiltoreservoirsorletit

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or bladepulley.

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

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

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

3.Mowerdeckisnotlevel.

4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley .

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

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

6.ContactanAuthorizedServiceDealer.

Bladesdonotrotate.

Clutchwillnotengage.

1.Mowerdeckbeltisworn,looseor broken.

2.Mowerdeckbeltisoffpulley.

3.Pumpdrivebeltisworn,looseor broken.

4.Brokenormissingidlerspring.4.Replacethespring.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.3.Replaceclutch.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

1.Installnewdeckbelt.

2.Installmowerdeckpulleyandcheck theidlerpulley,idlerarmandspringfor correctpositionandfunction.

3.Checkthebelttensionorinstallnew belt.

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

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

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Page 66

Schematics

WireDiagram(Rev.A)

Page 67

Notes:

Page 68

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment(LCE)

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuanttoan agreementbetweenthem,jointlypromisetotheoriginalpurchasertorepairtheToro Productslistedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers

•Engines

21in.Mowers2yearsResidentialUse

•Engines

30in.Mowers

•Engines

Mid-SizeWalk-BehindMowers

•Engines

GrandStand

•Engines

Mowers

•Frame

ZMaster

•Engines

2000SeriesMowers

•Frame

ZMaster

•Engines

3000SeriesMowers

•Frame

ZMaster

•Engines

5000SeriesMowers

•Frame

ZMaster

•Engines

6000SeriesMowers

•Frame

ZMaster

•Engines

7000SeriesMowers

•Frame

AllMowers

•Battery90daysPartsandLabor

•BeltsandTires90days

•Attachments1year

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforparts andlabor .Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor corrosionarenotcovered.

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer.

1yearCommercialUse

Honda–1years

Kawasaki–3years

Honda–2years

Kawasaki–3years

2yearsCommercialandResidentialUse

Kawasaki–3years

2years

Kawasaki–3years

5yearsor1,200hours

Kawasaki–3years

KohlerEFI–3years

Lifetime(originalowneronly)

4yearsor500hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

KohlerCommand–2years

KohlerEFI–3years

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

KohlerCommand–2years

KohlerEFI–3years

Lifetime(originalowneronly)

4yearsor1,200hours

Kubota–2years

Briggs&Stratton–2years

Lifetime(originalowneronly)

1yearPartsonly

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpaytransportation costs.

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir dealership.T olocateadealerconvenienttoyou,refertotheY ellowPagesof 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,MN55420-1196

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

888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures describedintheOperator'sManual.Suchroutinemaintenance,whetherperformed byadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystem andenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:

•Costofregularmaintenanceserviceorwearparts,suchaslters,fuel,

lubricants,tune-upparts,bladesharpening,brakeandclutchadjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear,accidents,orlackofproper maintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuelsystem,or

failuretoproperlypreparethefuelsystempriortoanyperiodofnon-useover threemonths.

•Pickupanddeliverycharges.

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro ServiceDealerusingT oroapprovedreplacementparts.

NeitherTheToroCompanynorT oroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro Productscoveredbythiswarranty ,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistforordinary use)andtnessforuse(thattheproductistforaparticularpurpose)are limitedtothedurationoftheexpresswarranty.

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.

374-0252RevE

Toro 74936, 74938 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SafeOperatingPractices

AddingFuel

BreakingInaNewMachine

UsingtheRolloverProtection System(ROPS)

CheckingtheEngineOilLevel

ThinkSafetyFirst

OperatingtheParkingBrake

OperatingtheMowerBlade ControlSwitch(PTO)

OperatingtheThrottle

OperatingtheChoke

OperatingtheIgnitionSwitch

UsingtheFuelShut-OffValve

StartingandStoppingthe Engine

TheSafetyInterlockSystem

DrivingForwardorBackward

StoppingtheMachine

AdjustingtheHeightofCut

AdjustingtheAnti-Scalp Rollers

PositioningtheSeat

UnlatchingtheSeat

UsingtheDriveWheelRelease Valves

UsingtheSideDischarge

LoadingMachines

TransportingMachines

GreasingandLubrication

WheretoGreasetheMower

LubricateCasterWheelHubs

ServicingtheAirCleaner

ServicingtheEngineOil

ServicingtheSparkPlug

ReplacingtheFuelFilter

ServicingtheFuelTank

ServicingtheBattery

ServicingtheFuses

CheckingtheSeatBelt

CheckingtheRollover ProtectionSystem(ROPS) Knobs

AdjustingtheTracking

CheckingtheWheelLugNuts

CheckingtheWheelHub SlottedNut

CheckingtheTirePressure

AdjustingtheCasterPivot Bearing

UsingtheClutchShim

CleaningtheEngineScreen

ServicingtheEngineOil Cooler

CleaningtheEngineCooling FinsandShrouds

CheckandCleantheHydraulic UnitShrouds

AdjustingtheParkingBrake

InspectingtheBelts

ReplacingtheMowerBelt

ReplacingtheHydraulicPump DriveBelt

AdjustingtheControlHandle Position

AdjustingtheMotionControl Linkage

AdjustingtheMotionControl NeutralLockPivot

AdjustingtheMotionControl Damper

ServicingtheHydraulic System

LevelingtheMowerDeck

ServicingtheCuttingBlades

RemovingtheMowerDeck

CleaningUndertheMower

WasteDisposal

CleaningandStorage