Toro 74951 Operator's Manual

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Page 1

FormNo.3367-967RevD

ZMaster

G3RidingMower

witha48inor52inTURBOFORCE DischargeMower

ModelNo.74951—SerialNo.311000001andUp

ModelNo.74952—SerialNo.311000001andUp

ModelNo.74953—SerialNo.311000001andUp

Side

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

Page 2

WARNING

agriculturaluses.

properties.Itisnotdesignedforcuttingbrushorfor

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002

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

GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.

Note:ItisaviolationofCaliforniaPublicResource CodeSection4442touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndingadealer, ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts, oradditionalinformation,contactanAuthorized ServiceDealerorToroCustomerServiceandhave themodelandserialnumbersofyourproductready . Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

WARNING

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

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

Theenclosed

Engine Owner's Man ual

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

Introduction

Thisrotary-blade,ridinglawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional,hired operators.Itisdesignedprimarilyforcuttinggrasson well-maintainedlawnsonresidentialorcommercial

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjury ordeathifyoudonotfollowtherecommended precautions.

Figure2

1.Safetyalertsymbol

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Page 3

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

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............................18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

CheckSparkArrester(ifequipped)......................38

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

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

ServicingtheFuelTank......................................39

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

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

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

DriveSystemMaintenance.....................................42

CheckingtheSeatBelt........................................42

CheckingtheRolloverProtectionSystem

(ROPS)Knobs...............................................42

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

CheckingtheTirePressure.................................43

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

AdjustingtheCasterPivotBearing......................44

UsingtheClutchShim........................................44

CoolingSystemMaintenance..................................46

CleaningtheEngineScreenandEngineOil

Cooler............................................................46

CleaningtheEngineCoolingFinsand

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

CheckandCleantheHydraulicUnits..................47

BrakeMaintenance.................................................48

AdjustingtheParkingBrake................................48

BeltMaintenance....................................................49

InspectingtheBelts............................................49

ReplacingtheMowerBelt...................................49

ReplacingtheHydraulicPumpDrive

Belt................................................................50

ControlsSystemMaintenance.................................51

AdjustingtheControlHandlePosition................51

AdjustingtheMotionControlLinkage................51

AdjustingtheMotionControlDamper...............52

AdjustingtheMotionControlNeutralLock

Pivot..............................................................52

HydraulicSystemMaintenance...............................53

ServicingtheHydraulicSystem...........................53

MowerDeckMaintenance......................................55

LevelingtheMowerDeck...................................55

ServicingtheCuttingBlades...............................57

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

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

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

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

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

Storage.......................................................................62

CleaningandStorage..........................................62

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

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

Page 4

Safety

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

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

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatchingcut grass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

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

Operation

•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator'sposition.Useseatbelts.

•Neverraisemowerwiththebladesrunning.

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

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

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

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Nevercarrypassengersandkeeppetsandbystanders away.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.

•Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.

Page 5

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

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

•Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

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

•Reducespeedanduseextremecautiononslopes.

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

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

•Avoidsuddenstartswhenmowinguphillbecausethe mowermaytipbackwards.

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

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.

•Followthemanufacturer'srecommendationsfor wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

•Keeptherollbarintheraisedandlockedposition andusetheseatbeltwhenoperatingthemachine.

•Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.

•Beawarethereisnorolloverprotectionwhenthe rollbarisdown.

•Checktheareatobemowedandneverfoldthe ROPSinareaswherethereareslopes,dropoffsor water.

•Lowertherollbaronlywhenabsolutelynecessary. Donotweartheseatbeltwiththerollbarfolded down.

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

Maintenanceandstorage

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

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

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

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

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.Wear protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

•UseonlyT oroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

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

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

68-8340

1-403005

98-5954

103-2076

54-9220

58-6520

1.Grease

105-7798

66-1340

Page 8

109-7929

110-2067

107-2102

110-2068

1.ReadtheOperator'sManual.

114-4466

1.Main,25A

109-7232

2.PTO,10A

3.Charge,25A

4.Auxiliary,15A

Page 9

1.Greasepulleysandspindles

2.Maintenanceinterval—50hours

116-1654

115-7445

116-1716

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresenceswitch

116-2643

116-0205

116-0211

116-2927

1.Latch

2.Unlatch

Page 10

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

116-3303

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe distancefromthebattery.

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

10.Containslead;donot discard.

116-4858

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

109-7069

Page 11

119-6662

1.Choke4.Continuousvariablesetting

2.PowerT ake-off(PTO)5.Slow

3.Fast

Page 12

ProductOverview

G014939

G008951

G008950

12

Usethesetimesforschedulingregularmaintenance (Figure6).

FuelGauge

Thefuelgaugeislocatedwiththehourmeterandthe barslightupwhentheignitionswitchison(Figure6).

Theindicatorlightappearswhenthefuellevelislow (approximatelyonegallonremaininginthefueltank).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheindicate withablacktrianglethattheinterlockcomponentisin thecorrectposition(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).

BatteryIndicatorLight

IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure6).

Figure6

Figure5

1.PTOSwitch4.Hourmeter/Safety

2.Choke

3.Throttlecontrol6.Fuses

5.Ignitionswitch

interlockdisplay/Fuel gauge

HourMeter

Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning.

1.Fuelgauge(bars)4.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

5.Lowfuelindicatorlight

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.Pullthechoke knobuptoengageit.

Page 13

BladeControlSwitch(PTO)

Length:

Thebladecontrolswitch(PTO)isusedtoengagethe electricclutchanddrivethemowerblades.Pullthe switchuptoengagethebladesandrelease.Todisengage theblades,pushthebladecontrolswitch(PTO)down ormoveamotioncontrolleverintotheneutrallock position.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.

48inchDeck52inchDeck

RollBar-Up

RollBar-Down

79.2inches(201.2 cm)

80.9inches(205.5 cm)

79.2inches(201.2 cm)

80.9inches(205.5 cm)

Height:

RollBar-UpRollBar-Down

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

Weight:

48inchDeck52inchDeck

20HPKawasaki Units

22HPKawasaki Units

24HPKawasaki Units

1048lb(475kg)

1085lb(492kg)

FuelShut-offValve

Closethefuelshut-offvalve(undertheseat)when transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Width:

48inchDeck52inchDeck

WithoutDeck

DeectorUp54inches(137.2

DeectorDown63.55inches(161.4

45.7inches(116.1 cm)

cm)57.5

cm)

45.7inches(116.1 cm)

57.5inches(146.0 cm)

67.63inches(171.8 cm)

Page 14

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

Useunleadedregulargasolinesuitableforautomotive use(85pumpoctaneminimum).Leadedregular gasolinemaybeusedifunleadedregularisnotavailable.

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

DANGER

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

DANGER

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

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•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.

•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditioneropening .

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner tothegas.

Page 15

Note:Afuelstabilizer/conditionerismosteffective

G009189

G012429

whenmixedwithfreshgasoline.T ominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.

FillingtheFuelTank

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking theEngineOilLevel.

Note:Donotllthefueltankcompletelyfull.Fillthe fueltanktothebottomofthellerneck.Theempty spaceinthetankallowsthegasolinetoexpand.

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefueltankcap.

4.Fillthefueltanktothebottomofthellerneck. Ensurethereisemptyspaceinthetanktoallowthe gasolinetoexpand(Figure7).

BreakingInaNewMachine

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

UsingtheRolloverProtection System(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keepthe rollbarintheraisedlockedpositionandusethe seatbelt.

Ensuretheseatissecuredtothemachine.

WARNING

Thereisnorolloverprotectionwhentherollbar isinthedownposition.

Figure7

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbaris inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearancepermits.

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

Important:Lowertherollbaronlywhen absolutelynecessary.

Important:Ensuretheseatissecuredtothe machine.

1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sotheyare notengaged(Figure8).

3.Lowertherollbartothedownposition(Figure8).

Page 16

DANGER

Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Thereisnorolloverprotectionwhentherollbar isdown.

Alwayskeeptherollbarintheraisedandlocked positionandusetheseatbelt.

Readandfollowtherolloverprotectioninstructions andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan 15degrees.

•Reducespeedanduseextremecautionon slopes.

Figure8

1.ROPSknob

2.PullROPSknoboutand rotate90degrees

3.Rollbarintheupright position

4.Rollbarinthefolded position

4.Toraisetherollbar,raisetherollbartotheoperate position,rotatetheknobssotheymovepartially intothegrooves(Figure8).

5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins

Figure8).Pushontherollbarandensurethat

( bothpinsareengaged.

Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.

•Avoidsuddenturnsorrapidspeedchanges.

Figure9

1.SafeZone-usethe ZMasterhereonslopes lessthan15degreesor atareas.

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

3.Water

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.

Page 17

CAUTION

G009027

G008960

G008944

G008945

Thismachineproducessoundlevelsinexcessof 85dBAattheoperatorsearandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Theuseofprotectiveequipmentforeyes,ears,feetand headisrecommended.

Figure10

Figure12

1.Wearsafetyglasses

2.Wearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.

SettingtheParkingBrake

WARNING

Parkingbrakemaynotholdmachineparkedona slopeandcouldcausepersonalinjuryorproperty damage.

Donotparkonslopesunlesswheelsarechocked orblocked

OperatingtheMowerBlade ControlSwitch(PTO)

Thebladecontrolswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

EngagingtheBladeControlSwitch (PTO)

Note:Engagingthebladecontrolswitch(PTO)with

thethrottlepositionathalforlesswillcauseexcessive weartothedrivebelts.

Figure13

Figure11

ReleasingtheParkingBrake

Pushinthereleasebuttonbeforepushingdown.

Page 18

DisengagingtheBladeControlSwitch

G009174

G008946

G008959

START

RUN

STOP

G008947

(PTO)

Figure14

OperatingtheThrottle

ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(

Figure15).

Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).

Figure15

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostartthe engine.

2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(

Figure16).

Figure16

1.On2.Off

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition (Figure17).Whentheenginesstarts,releasethekey.

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

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure16).

Figure17

2.Turntheignitionkeytostoptostoptheengine.

UsingtheFuelShut-OffValve

Thefuelshut-offvalveislocatedundertheseat.Move theseatforwardtoaccessit.

Page 19

Closethefuelshut-offvalvefortransport,maintenance,

G008948

START

RUN

STOP

G008947

andstorage.

Ensurethefuelshut-offvalveisopenwhenstarting theengine.

Figure18

1.On2.Off

StartingandStoppingthe

Figure19

Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,sitonthe seatandfastentheseatbelt.

2.Movethemotioncontrolstoneutrallocked position.

3.Settheparkingbrake;refertoSettingtheParking Brake.

4.Movethebladecontrolswitch(PTO)totheOff position(

5.MovethethrottlelevermidwaybetweentheSlow andFastpositions.

Figure19).

6.TurntheignitionkeytotheStartposition Figure17).Whentheenginesstarts,releasethekey.

(

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

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.

Figure20

1.Off3.Start

2.Run

Page 20

StoppingtheEngine

G009181

TheSafetyInterlockSystem

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Theparkingbrakeisengaged.

•Thebladecontrolswitch(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked position

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOisengaged.

Figure21

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine, asfuelleakagemayoccur.Settheparkingbrake beforetransporting.Makesuretoremovethekey asthefuelpumpmayrunandcausethebattery tolosecharge.

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.

Figure22

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorizedService Dealerrepairthesafetysystemimmediately .

Page 21

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

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

3.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, releasetheparkingbrake,engagethebladecontrol switch(PTO)andriseslightlyfromtheseat;the engineshouldstop.

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

UsingtheMotionControlLevers

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

DrivingForwardorBackward

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

CAUTION

Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

Figure23

1.Motioncontrol lever-neutrallockposition

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

DrivingForward

Note:Theenginewillkillifthetractioncontrollevers

aremovedwiththeparkingbrakeengaged.

Tostop,pullthemotioncontrolleverstotheneutral position.

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotioncontrol leversforward(

Figure24).

Page 22

G008952

G008953

StoppingtheMachine

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

Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Figure24

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure25).

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhastwopositionsandisusedwith thedeckliftpedal.Thereisalockpositionandaunlock positionforthetransportposition.Thetransportlock isusedwiththedeckliftpedal.Referto

Figure26

Figure25

Page 23

AdjustingtheHeight-of-CutPin

G014940

Theheight-of-cutisadjustedfrom1-1/2to4-1/2inches (38to114mm)in1/4inch(6mm)incrementsby relocatingtheclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfootandraise themowerdecktothetransportposition(also the4-1/2inch(114mm)cuttingheightposition)

Figure27).

(

3.Toadjust,rotatethepin90degreesandremovethe pinfromtheheight-of-cutbracket(

4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(Figure27).

5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.

Figure27).

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,itis recommendedtoadjusttheheightoftheanti-scalp rollers.

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Page 24

Figure28

G008961

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

AdjustingtheFlowBafeCam Locks

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

Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlocksand bafetogivethebestqualityofcut.

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Toadjustthecamlocks,swingtheleverupto loosenthecamlock(

4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow .

5.Swingtheleverbackovertotightenthebafeand camlocks(Figure31).

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

Figure31).

Figure29

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

Figure30

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

Figure31

1.Unlocklever

2.Rotatethecamlockto increaseordecrease lockingpressure

3.Positionthebafe

4.Locklever

PositioningtheFlowBafe

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

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

Page 25

PositionA

G008962

Thisisthefullrearposition.Thesuggesteduseforthis positionisafollows.

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe mower.

Figure32

•Allowsincreasedgroundspeedinheavyconditions.

•ThispositionissimilartothebenetsoftheT oro SFSmower.

Figure34

PositionB

Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.

Figure33

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.

Toadjust,movetheleversidewaystounlockseat (Figure35).

Figure35

UsingtheDriveWheelRelease

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows.

•Useintall,densegrassmowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

Valves

WARNING

Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury.

Stoptheengine,removethekey,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.

Page 26

WARNING

g015123

DANGER

Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulicdrive unitscancausesevereburns.

Allowtheengineandhydraulicdriveunitstocool completelybeforeaccessingthedrivewheelrelease valves.

Thedrivewheelreleasevalvesarelocatedinthebackof eachhydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefully horizontalpositionwhenoperatingthemachineor severedamagetothehydraulicsystemcanoccur.

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

2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthe pumpenablingthewheelstoturn(

Figure36).

3.Disengageparkingbrakebeforepushing.

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

•Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthemower.

•Nevertrytoclearthedischargeareaormower bladesunlessyoumovethepowertakeoff (bladecontrolswitch(PTO)totheoffposition, rotatetheignitionkeytooffandremovethekey .

•Makesurethegrassdeectorisinthedown position.

TransportingMachines

Figure36

1.Verticaltopushthe machine

2.Horizontaltorunthe machine

4.Rotatethereleasevalvelevershorizontallytorun themachine(Figure36).

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

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

WARNING

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

Donotdrivemachineonapublicstreetorroadway.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

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

Page 27

1.Tractionunittiedownloops

Figure37

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure38). Thelowerrearsectionofthetractorframeextendsback betweentherearwheelsandservesasastopfortipping backward.Havingafullwidthrampprovidesasurface fortheframememberstocontactiftheunitstartsto tipbackward.Ifitisnotpossibletouseonefullwidth ramp,useenoughindividualrampstosimulateafull widthcontinuousramp.

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

Figure38).Asteeperangle

Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

Page 28

WARNING

Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.

•Useextremecautionwhenoperatingauniton aramp.

•EnsuretheROPSisintheuppositionwhile usingtheseatbeltwhenloadingthemachine. EnsuretheROPSwillclearthetopofan enclosedtrailer.

OperatingTips

FastThrottleSetting

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

•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•Donotexceeda15degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.

•Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

CuttingaLawnfortheFirstTime

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

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

MowatCorrectIntervals

Figure38

1.Trailer3.Notgreaterthan 15degrees

2.Fullwidthramp4.Fullwidthramp—sideview

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

CuttingSpeed

Toimprovecutquality ,useaslowergroundspeedin certainconditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.

Page 29

LongGrass

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

WhenStopping

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

KeeptheUndersideoftheMower Clean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

BladeMaintenance

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

Page 30

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst100hours

Beforeeachuseordaily

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Checktheparkbrakeadjustment.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunits.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Check,cleanandregapthesparkplug.

•Checkandcleanenginecoolingnsandshrouds.

Every200hours

Every250hours

Every500hours

Monthly

Yearly

Yearlyorbeforestorage

•Lubricatethebrakehandlepivotwithlightoil.

•Changetheengineoillter.

•Replacetheprimaryairlter .

•Checkthesecondaryairlter(22hpand24hpEnginesOnly).

•ChangethehydraulicltersandhydraulicoilwhenusingMobil®1oil.

•Replacethesecondaryairlter(22hpand24hpEnginesOnly).

•Replacethefuellter.(moreoftenindirtyordustyconditions).

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Adjustthecasterpivotbearing.

•Checktheparkbrakeadjustment.

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

•Checkthebattery .

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

Page 31

CAUTION

G014941

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy .

GreaseType:No.2generalpurposelithiumbaseor molybdenumbasegrease

HowtoGrease

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

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

5.Wipeupanyexcessgrease.

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every100hours

Every200hours

•Brakehandlepivot.

•Deckliftpivots.

Figure39

WheretoGreasetheMower

ServiceInterval:Every50hours—Greasethemower

deckspindlesandidlerarm.

Yearly—Greasethepumpbeltidler arm.

Yearly—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).

Yearly—Repackthefrontcaster wheelbearings(moreoftenindirtyor dustyconditions).

Important:Makesurecuttingunitspindlesarefull ofgreaseweekly.

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

Page 32

2.Stoptheengine,removethekey,andwaitforall

G009029

g014942

movingpartstostopbeforeleavingtheoperating position.

3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(

Figure40).

4.Greasethethreespindlebearingsuntilgreasecomes outthelowerseals(Figure40).

Figure40

Figure42

LubricateCasterWheelHubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.

5.Greasethedrivebeltidlerarm(Figure41).

Figure41

6.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.

7.Removethehexplug.Threadagreasezerkintothe hole.

8.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

9.Removethegreasezerkinthehole.Installthehex pluganddustcap(Figure42).

Figure43

1.Sealguard2.Spacernutwithwrench ats

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

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

5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.

6.Packthebearingswithageneral-purposegrease.

7.Insertonebearing,onenewsealintothewheel.

Note:Thesealsmustbereplaced.

8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontotheaxle withthewrenchatsfacingoutward.DoNotthread

Page 33

spacernutallofthewayontotheendoftheaxle. Leaveapproximately1/8inch(3mm)fromtheouter surfaceofthespacernuttotheendoftheaxleinside thenut.

9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.

11.Insertthesecondbearingandnewsealintothe wheel.

12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.

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

14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .

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

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacethe

primaryairlter.

Every250hours—Checkthe secondaryairlter(22hpand24hp EnginesOnly).

Every500hours—Replacethe secondaryairlter(22hpand24hp EnginesOnly).

Note:Servicetheaircleanermorefrequentlyif operatingconditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pushdowntoreleasetheretainingclampsontheair cleanerandpulltheaircleanercoveroffoftheair cleanerbody(

4.Cleantheinsideoftheaircleanercoverwith compressedair.

5.Gentlyslidetheprimarylteroutoftheaircleaner

Figure44).Avoidknockingthelterintothe

body( sideofthebody.

6.For22hpand24hpenginesonly,removethe secondarylteronlyifyouintendtoreplaceit.

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

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

Figure44).

Page 34

Figure44

1.Aircleanerclamps

2.Aircleanercover

3.Primaryairlter

4.Secondaryairlter(22hp and24hpEnginesOnly)

ServicingthePrimaryFilter

1.Donotcleanthepaperlter,replaceit(Figure44).

Important:Donotpressonthesoftinsidearea ofthelter.

4.Installtheaircleanercoverwiththebreathercap downandrotatesotheretainingclampslockthe coverinplace(

Figure44).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSF,SG,SH,SJ, orSL)

CrankcaseCapacityfor20hpEngines:withalter change,58ounces(1.7L);withoutalterchange,51 ounces(1.5L)

CrankcaseCapacityfor22hpand24hpEngines:

withalterchange,71ounces(2.1L);withoutalter change,61ounces(1.8L)

Viscosity:Seethetablebelow .

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

ServicingtheSecondaryFilter(22hp and24hpEnginesOnly)

Donotcleanthesecondarylter,replaceit.

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

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandcover installed.

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

2.Ifthesecondarylter(22hpand24hpEnginesOnly) isbeingreplaced,carefullyslideitintothelterbody (Figure44).

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

Figure45

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

10W-40)willincreaseoilconsumption.Checktheoil levelmorefrequentlywhenusingthem.

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.

Page 35

1.DisengagethePTO ,movethemotioncontrollevers

G008804

G008792

G008804

G008793

totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure46).

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirty ordustyconditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.

2.Parkthemachinesothattherearisslightlylower thanthefronttoensuretheoildrainscompletely.

3.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure47).

Figure46

Figure47

Page 36

5.Slowlypourapproximately80%ofthespeciedoil

G008796

G008804

G008748

3/4

intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure48).

Figure48

6.Starttheengineanddrivetoaatarea.Checkthe oillevelagain.

ChangingtheEngineOilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Changetheengineoillter(

Figure49).

Figure49

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

3.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.

Page 37

ServicingtheSparkPlug

g015124

G008794

ServiceInterval:Every100hours

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

Figure51

TypeofSparkPlug:NGK

AirGap:0.030inch(0.75mm)

BPR4ESorequivalent

RemovingtheSparkPlug

1.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

2.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Locateandremovethesparkplugs(

Figure50).

InstallingtheSparkPlug

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

Figure52

Figure50

CheckingtheSparkPlug

Important:Nevercleanthesparkplug(s).Always

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

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.

Setthegapto0.030inches(0.76mm).

Page 38

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:Every500hours/Yearly(whichever

comesrst)(moreoftenindirtyor dustyconditions).

Thefuellterislocatedneartheengineonthefront orrearsideoftheengine.

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Allowthemachinetocooldown.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

5.Closethefuelshutoffvalveundertheseat (Figure53).

Figure53

1.Fuellter

2.Hoseclamp

6.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure53).

7.Removethelterfromthefuellines.

8.Installanewlterandmovethehoseclampsclose tothelter(

9.Openthefuelshutoffvalve.

Figure53).

3.Fuelline

Page 39

Note:Itisimportanttoreinstallthefuellinehosesand securewithplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineawayfrom componentsthatcouldcausefuellinedamage.

ElectricalSystem Maintenance

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.

ServicingtheBattery

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

W ash hands after handling .

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.

•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

Page 40

WARNING

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.

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(

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

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

4.Securethecableswith2bolts,2washers,and 2locknuts(

Figure54).

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.Installtheclampandsecureitwiththewingnut

Figure54).

(

Figure54).

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

Figure54).

(

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

Figure54).

5.Removethewingnutsecuringthebatteryclamp (Figure54).

6.Removetheclamp(Figure54).

7.Removethebattery.

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.

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

1.Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.

2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(

3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.

Figure55).

1.Removethewingnutand clamp

2.Removethenegative batterycablebeforethe positive

Figure54

3.Removethepositive batterycable

4.Removebattery

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

Page 41

Figure55

ServicingtheFuses

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

1.Thefusesarelocatedonrighthandconsolenextto theseat(

2.Toreplacethefuses,pulloutonthefusetoremove it.

3.Installanewfuse(Figure56).

Figure56).

1.PositiveBatteryPost

2.NegativeBatteryPost

3.Red(+)ChargerLead

4.Black(-)ChargerLead

Figure56

1.Optionalaccesory-15amp

2.Charge-25amp5.Console

3.PTO-10amp

4.Main-25amp

Page 42

DriveSystem Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

Checkthatboththemountinghardwareandtheknobs areingoodworkingcondition.Makesuretheknobs arefullyengagedwiththeROPSintheraisedposition. Theupperhoopoftherollbarmayneedtobepushed forwardorpulledrearwardtogetbothknobsfully engaged.

Figure57

1.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(Figure58).

Page 43

7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplaterearwardontherightT-slotuntilthe machinetracksstraight(Figure58).

8.Tightenthestopplate(

Figure58).

Figure59

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

Figure60todeterminewhichslottednuthasbeen

See installedontheunit.

Figure58

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthefrontandreartiresat 13psi(90kPa).Uneventirepressurecancauseuneven cut.Checkthetireswhentheyarecoldtogetthemost accuratepressurereading.

Figure60

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

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

•StyleA(blacknish):

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

Note:DoNotuseanti-seizeonwheelhub.

•StyleB(yellowzinc):

1.Removeanddiscardthecotterpin.

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

3.Checkdistancefrombottomofslotinnutto insideedgeofhole.Twothreads(0.1inch)or lessshouldbeshowing.

Page 44

Figure61

1.0.1inchmax2.Nomorethantwothreads (0.1inchmax)shouldbe showinghere.

4.Ifmorethantwothreads(0.1inch)areshowing removenutandinstallwasherbetweenhuband nut.

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

6.Thentightennutuntilthenextsetofslotsline upwiththecrossholeinshaft.Donotloosen nuttoaligntheslot.Ifrequired,tightentothe nextsetofslots.

7.Installanewcotterpin.

Note:DoNotuseanti-seizeonwheelhub.

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

Figure62

1.SpringWashers3.DustCap

2.LockNut

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwithclutches thatcontainabrakeshim.Whentheclutchbrakehas worntothepointwheretheclutchnolongerengages consistently,theshimcanberemovedtoextendthe clutchlife.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethedustcapfromcasterandtightenlock

Figure62).

nut(

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

Important:Makesurethespringwashersare installedcorrectlyasshowninFigure62.

5.Installthedustcap(Figure62).

Figure63

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheClutchShim

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

Page 45

2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.

Figure66

1.Shim

Figure64

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

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

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

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

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.)

Figure67

1.Feelergauge

Figure65

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,takehold

ofthetabandremovetheshim(DoNotdiscard theshimuntilproperclutchfunctionhasbeen conrmed).

Figure68

1.Feelergauge

Page 46

•Ifthegapislessthan0.010inch,thenreinstall

G008804

theshimandreferencetheTroubleshooting section.

•Ifthegapissufcient,proceedtothesafety checkinstep

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewiththe

PTOswitch“off”andtheclutchdisengaged.

Iftheclutchdoesnotdisengage,reinstallthe shimandreferencetheTroubleshooting section.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly ,referencethe Troubleshootingsection.

CoolingSystem Maintenance

CleaningtheEngineScreen andEngineOilCooler

ServiceInterval:Beforeeachuseordaily

Removeanybuild-upofgrass,dirtorotherdebrisfrom theoilcooler(Figure69).

Figure69

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

Figure70).

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every100hours/Yearly(whichever

comesrst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removetheairintakescreen,recoilstarterandfan housing(Figure70).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing (

Figure70).

Page 47

Figure70

g0151 17

1.Engineguard4.Fanhousing

2.Engineairintakescreen

3.Bolt

5.Screw

CheckandCleantheHydraulic Units

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Movetheseatforward.

4.Cleanthedebrisandgrassfromthehydraulicunits

Figure71).

(

5.Positiontheseat.

Figure71

1.Hydraulicunits

Page 48

BrakeMaintenance

standardnut.DoNotallowthecabletoturnwhen thenutsaretightened.

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hours

DANGER

Mechanicalorhydraulicjacksmayfailtosupport machineandcauseaseriousinjury .

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

Checktomakesurethebrakeisadjustedproperly.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,waitforallthemovingpartstostop, andremovethekey.

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

15.Closethedrivewheelreleasevalve.RefertoUsing theDriveWheelValvesinOperation.

16.Repeatontheoppositesideofthemachine.

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

18.Removejackstands.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Openthedrivewheelreleasevalves.RefertoUsing theDriveWheelValvesinOperation.

8.Disengagetheparkingbrake.

9.Usinghandsandngersonly ,pushthecaliperlever armtoengagethebrakepadsontherotoruntilthe leverstops(

Figure72).

Notetheorderofthestandardnutandlocknut.

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

Figure72).

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

12.Ifthereisnomovementbetweenthehubrotorand thecaliperthenbackoffthestandardnutoneturn fromtheswivelandrepeatstep11

Figure72

LeftHandBrakeShown

1.Cableanchor

2.Threadedrod7.Pullcablethreadedrod

3.Pushleverthisdirection8.Holdthreadedrodhere

4.Caliperleverarm9.Swivel(pivothead)

5.Standardnut(shown againstswivel)

6.Locknut

thisdirection

13.Ifthehubrotormovesveryfreelyrelativetothe caliper,thentightenthestandardnutoneturn againsttheswivelandrepeatstep

14.Oncestep11isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainstthe

Page 49

BeltMaintenance

G009036

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating, bladesslippingwhencuttinggrass,frayedbeltedges, burnmarksandcracksaresignsofawornmowerbelt. Replacethemowerbeltifanyoftheseconditionsare evident.

ReplacingtheMowerBelt

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

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Lowerthemowertothe3inch(76mm)heightofcut.

4.Removethebeltcovers(

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(Figure74).

6.Removethebeltfromthemowerdeckpulleys.

7.Removethebeltguideonthespringloadedidlerarm showninFigure74.

Figure73).

Figure73

Figure74

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

10.Installthebeltguideontheidlerarmshownin Figure74.

11.Usingtheratchetinthesquarehole,installtheidler spring(Figure74).

Makesurethespringendsareseatedintheanchor grooves.

12.Installthebeltcovers(

armfortheratchet

7.Beltguide

Figure75).

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysand theclutchpulleyundertheengine(Figure74).

Page 50

Figure75

1.Positionthebeltcover3.Ensurethetabisunder

2.Slidebeltcoverunderthe sidecatches

themetalcatch

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.

4.Raisethemachineandsupportitwithjackstands

Figure76).

(

Figure76

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump pulley

5.Lefthandhydraulicpump pulley

5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure76).

6.Unhooktheidlerspringfromtheframe(

Figure76).

7.Removethebeltfromthehydraulicunitdrivepulleys andtheenginepulley

8.Installthenewbeltaroundenginepulleyandthetwo drivepulleys.

9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(

Figure76).

10.Installthemowerbelt.RefertoReplacingtheMower Belt.

Page 51

ControlsSystem Maintenance

AdjustingtheControlHandle Position

Therearetwoheightpositionsforthecontrollevers; highandlow .Removetheboltstoadjusttheheightfor theoperator.

1.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Loosentheboltsandangenutsinstalledinthe levers(

Figure77).

Figure78

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslide themuntiltheyarealigned,thentightenthebolts

Figure78).

(

Figure77

1.Bolt

2.Handle4.Nut

3.Controllever

AdjustingtheMotionControl Linkage

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

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearofrotating componentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdeckto theground.

2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushionof theseat.Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedandmotion

controlleversouttostartengine.Operatordoes

Page 52

nothavetobeintheseatbecauseofthejumper

g014943

wirebeingused.Runengineatfullthrottleand releasebrake.

AdjustingtheMotionControl Damper

6.Runtheunitatleast5minuteswiththedrivelevers atfullforwardspeedtobringhydraulicoilupto operatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsby rotatingthedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepinreverse

Figure79).Movethemotioncontrolleverstothe

( reversepositionandwhileapplyingslightpressureto theleverallowthereverseindicatorspringstobring theleversbacktoneutral.Thewheelsmuststop turningorslightlycreepinreverse.

Thetopdampermountingboltcanbeadjustedtoobtain amoredesiredmotioncontrolleverresistance.See Figure80formountingoptions.

Figure80

RHMotionControlShown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

Figure79

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

AdjustingtheMotionControl NeutralLockPivot

Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittothe neutrallockposition.SeeFigure81foradjustment options.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

Page 53

HydraulicSystem Maintenance

ServicingtheHydraulic System

Figure81

1.Flangednut2.Jamnut

115W-50.

HYPR-OIL

HydraulicOilType:Toro hydraulicoilorMobil

Important:Useoilspecied.Otheruidscould causesystemdamage.

EachHydraulicSystemOilCapacity:52ounces(1.5

l)persidewithlterchange

™

500

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulic

oillevel.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO ,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Allowtheengineandhydraulicsystemtocoolfor tenminutes.

Note:Theoillevelonthedipstickwillbeincorrect whentheoilischeckedandtheunitishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofhydraulic systemreservoirs(

7.Removeonedipstickfromthehydraulicreservoir

Figure82).

(

8.Wipethedipstickoffandthreadthedipstickinto thereservoir.

9.Removethedipstickandlookattheend( Iftheoillevelisattheaddmark,slowlypouronly enoughoilintothehydraulicreservoirtoraisethe leveltothefullorHline.

Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewiththeoilbelowtheaddmark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

Figure82).

Page 54

G015459

ReplacingtheHydraulicFiltersand HydraulicOil

ServiceInterval:Every250hours—Changethe

hydraulicltersandhydraulicoil whenusingMobil

Every500hours—Changethe hydraulicltersandhydraulicoil whenusingToro hydraulicoil.

Toreplacethehydraulicoil,theltersneedtobe removed.Replacebothatthesametime.Refertotheoil specicationsunderServicingtheHydraulicSystemfor thecorrectoil.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

1oil.

HYPR-OIL

™

500

Figure82

Eitherdipstickwillbeusedinthemachine

1.Full3.H–meanshighlevel

2.Add4.Dipsticklocationsunder seat

WARNING

Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

3.Raisethemachineandsupportitwithjackstands Figure83).

(

Figure83

1.Jackstands

4.Removeboththemowerbeltandthepumpdrive

belt.Thiswillpreventoilgettingonthebelts.Refer toBeltsintheMaintenanceSection.

5.Placeadrainpanunderthelter,removetheold

lterandwipethesurfaceclean(Figure84).

Page 55

G008968

Figure84

BottomViewofMachine

1.Filterlocations

6.Applyathincoatofhydraulicoiltotherubber gasketonthereplacementlter(Figure84).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine

Figure83).

(

10.Addoiltothehydraulicreservoirandcheckforany leaks.

2.Hydrauliclter

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethemowerdeckisleveledbefore

matchingtheheight-of-cut(HOC).

1.Positionmoweronaatsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Checktirepressureofthetires.Ifneeded,adjustto 13psi(90kPa)

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

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey .Engageparkingbrake.

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

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Do notoverll.

4.Positionthetransportlockinthelatchingposition.

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

Figure85).

Page 56

G014940

Figure85

Toincreasetheheight,turntheadjusterscrew clockwise;todecrease,turncounterclockwise.

1.Deckliftpedal

2.Heightofcutpin

3.Transportlock

6.Inserttheheightadjustmentpinintothe3inch(7.6 cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargechute.

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

Figure87

1.Whizlocknut3.Jamnut

2.Adjusterscrew4.Y oke

11.Ifthefrontdecklinksdonothaveenoughadjustment toachieveaccuratecutheight,thesinglepoint adjustmentcanbeutilizedtogainmoreadjustment.

12.Toadjustthesinglepointsystem,loosenthetwo boltsatthebottomoftheheightofcutplate.Refer

Figure88.

Figure86

1.3inches(7.6cm)atAis correct

2.31/4inches(8.3cm)atB iscorrect

3.Measureherefromthe bladetiptohardsurface

4.MeasureatAandBon bothsides

10.Ifneeded,loosenthewhizlocknutonthesideofthe yokeandthejamnutontop.Finetunethescrew adjusterbyturningittoget3inch(7.6mm)height (seeFigure87).

Figure88

1.Boltsatthebottomoftheheight-of-cutplate

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

Page 57

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

Figure89

1.Singlepointadjustmentbolt

14.Tightenthetwoboltsatthebottomoftheheightof cutplate(Figure88).Torqueto27-33ft-lb(37-45 N-m).

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.

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

DANGER

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

Note:Inmostconditions,thebackbladetipshould

beadjusted1/4inch(6.4mm)higherthanthefront.

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

Figure86).

(

16.Finetunethescrewadjusterbyturningittoget 3–1/4inches(8.3mm)height(

Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

17.Measureuntilallfoursidesarethecorrectheight. Tightenallthenutsonthedeckliftarmassemblies.

18.Lowerdischargechute.

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

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

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

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

Figure90),immediatelyinstalla

Figure90

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

Page 58

CheckingforBentBlades

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

Figure91).Notethisdimension.

(

performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.

1.Holdthebladeendusingaragorthickly-padded glove.

2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(

Figure92).

Figure91

1.Measureherefromblade tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin

3and4mustnotexceed1/8inch(3mm).If

steps thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

Figure92

1.SailAreaofBlade3.Curvedwasher

2.Blade4.BladeBolt

SharpeningtheBlades

WARNING

Whensharpeningblade,piecesofbladecouldbe thrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpeningblade.

1.Usealetosharpenthecuttingedgeatbothends oftheblade( Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

Figure93).Maintaintheoriginalangle.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum

Page 59

Figure93

1.Sharpenatoriginalangle

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

Figure95).Repeatthis

procedureuntilthebladeisbalanced.

Figure94

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure95).

Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.

2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead

Figure95).Torquethebladeboltto85-110ft-lb

( (115-150N-m).

1.Blade2.Balancer

1.SailAreaofBlade

2.Blade

3.SpringDisk

Figure95

4.BladeBolt

5.ConeTowardsBoltHead

Page 60

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,thespring loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.

DoNotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.

1.Stopengine,waitforallmovingpartstostop,and removekey .Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe decktotheground.

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

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(

Figure96).

6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(

Figure96).

Figure96

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

armfortheratchet

7.Beltguide

7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure97.

Page 61

Figure97

g015594

6 2

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

Figure98

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring

5.Springinstalled

7.Jhookendofspring

8.Raisethedeckstrutsandsecurethemintheup position.Slidethedeckouttotherightsideofthe machine.

ReplacingtheGrassDeector

WARNING

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

Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.

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

2.Placespacerandspringontograssdeector.Place oneJendofspringbehinddeckedge.

Note:MakesureoneJendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown

Figure98.

3.Installboltandnut.PlaceoneJhookendofspring aroundgrassdeector(Figure98).

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

Page 62

Cleaning

Storage

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemowertothetransportposition.

WasteDisposal

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

CleaningandStorage

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

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

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

3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.

4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.

5.Greasethemachine;refertoGreasingand LubricationintheMaintenanceSection.

6.Changethecrankcaseoil;refertoServicingthe EngineOilintheMaintenanceSection.

7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.

8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.

9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.

10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:Runthemachinewiththebladecontrol switch(PTO)engagedandtheengineathighidlefor 2to5minutesafterwashing.

11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.

12.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachineforstorage asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandused atalltimes.

Page 63

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankinthe MaintenanceSection.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Important:Donotstore stabilizer/conditionedfuelover90days.

13.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

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

Page 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

TheToroCompanyanditsafliate,ToroWarrantyCompany ,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:

ProductsWarrantyPeriod

AllMowers

•Engine

Seeenginemanufacturer'swarranty

•Battery90daysPartsandLabor 1yearPartsonly

•BeltsandTires90days

•Attachments1year

21in.HeavyDutyMowers1yearcommercialUse

2yearsResidentialUse

Mid-SizeWalk-BehindMowers GrandStand

Mowers

•Frame

ZMaster

Z400,Z500Mowers4yearsor1,200hours

•Frame

ZMaster

G3Mowers

•Frame

SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer.

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply .

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe

tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin

normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforparts

andlabor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor

corrosionarenotcovered.

2years 5yearsor1,200hours Lifetime(originalowneronly)

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

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:

1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.T olocateadealerconvenienttoyou,refertotheYellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww.T oro.com.Youmayalsocallthenumbers listedinitem#3tousethe24-hourToroDealerlocatorsystem.

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:

RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator'sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:

•Costofregularmaintenanceserviceorwearparts,suchaslters,

fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel

system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.

•Pickupanddeliverycharges.

GeneralConditions

Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingToroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty

Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguarantee information,contacttheToroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany.

374-0252RevC