Toro 74991 Operator's Manual

FormNo.3396-233RevD

ZMaster

®

Professional5000

SeriesRidingMower

with60inTURBOFORCE
Mower

ModelNo.74991—SerialNo.315000001andUp

®

SideDischarge

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3396-233*D

ThissparkignitionsystemcomplieswithCanadian
ICES-002

Becauseinsomeareastherearelocal,state,or
federalregulationsrequiringthatasparkarresterbe
usedontheengineofthismachine,asparkarresteris
availableasanoption.Ifyourequireasparkarrester,
contactyourAuthorizedToroServiceDealer.

GenuineT orosparkarrestersareapprovedbythe
USDAForestryService.

Important:ItisaviolationofCaliforniaPublic

ResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,
orgrass-coveredlandwithoutasparkarrester
mufermaintainedinworkingorder,ortheengine
constricted,equipped,andmaintainedforthe
preventionofre.Otherstatesorfederalareas
mayhavesimilarlaws.

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

TheenclosedEngineOwner'sManualis
suppliedforinformationregardingtheUS
EnvironmentalProtectionAgency(EP A)and
theCaliforniaEmissionControlRegulationof
emissionsystems,maintenance,andwarranty.
Replacementsmaybeorderedthroughtheengine
manufacturer.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Introduction

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

g029954

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.

g000502

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Y ouareresponsiblefor
operatingtheproductproperlyandsafely .

YoumaycontactT orodirectlyatwww.T oro.com
forproductsafetyandoperationtrainingmaterials,
accessoryinformation,helpndingadealer,orto
registeryourproduct.

©2018—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

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

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

SlopeIndicator...................................................7

SafetyandInstructionalDecals..........................8

ProductOverview...................................................15

Controls...........................................................15

Specications..................................................16

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

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

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

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

UsingtheRolloverProtectionSystem

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

EnteringtheUserPosition................................19

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

OperatingtheParkingBrake.............................20

OperatingtheMowerBlade-ControlSwitch

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

OperatingtheThrottle.......................................21

OperatingtheIgnitionSwitch............................21

UsingtheFuel-ShutoffValve.............................22

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

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

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

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

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

AdjustingtheAnti-ScalpRollers........................27

AdjustingtheFlowBafeCamLocks................27

PositioningtheFlowBafe................................28

PositioningtheSeat..........................................29

UnlatchingtheSeat..........................................29

AdjustingtheMyRide™Suspension

System..........................................................29

UsingtheDriveWheelReleaseValves.............30

UsingtheSideDischarge.................................31

TransportingtheMachine.................................32

LoadingtheMachine........................................32

OperatingTips.................................................34

Maintenance...........................................................35

RecommendedMaintenanceSchedule(s)...........35

Lubrication..........................................................36

LubricatingtheMachine....................................36

GreasingtheMower.........................................36

LubricatetheCasterWheelHubs.....................38

EngineMaintenance...........................................39

ServicingtheAirCleaner..................................39

ServicingtheEngineOil....................................40

ServicingtheSparkPlugs.................................43

CheckSparkArrester(ifequipped)...................45

FuelSystemMaintenance...................................45

ServicingtheElectronicFuelInjection

System..........................................................45

ReplacingtheLow-PressureFuel

Filter..............................................................45

ServicingtheHigh-PressureFuelFilter.............46

ServicingtheFuelT ank.....................................46

ElectricalSystemMaintenance...........................46

ServicingtheBattery.........................................46

ServicingtheFuses..........................................48

Jump-StartingtheMachine...............................48

DriveSystemMaintenance..................................50

CheckingtheSeatBelt.....................................50

CheckingtheKnobsontheRollover

ProtectionSystem(ROPS)...........................50

AdjustingtheTracking......................................51

CheckingtheTirePressure...............................51

CheckingtheWheelLugNuts...........................52

CheckingtheWheelHubSlottedNut................52

AdjustingtheCasterPivotBearing....................52

UsingtheClutchShim......................................52

CoolingSystemMaintenance..............................54

CleaningtheEngineScreenandEngine-Oil

Cooler...........................................................54

CleaningtheEngineCoolingFinsand

Shrouds........................................................54

CheckandCleantheHydraulic-Unit

Shrouds........................................................55

BrakeMaintenance.............................................56

AdjustingtheParkingBrake..............................56

BeltMaintenance................................................57

InspectingtheBelts..........................................57

ReplacingtheMowerBelt.................................57

ReplacingtheHydraulicPumpDrive

Belt................................................................58

ControlsSystemMaintenance.............................59

AdjustingtheControlHandlePosition...............59

AdjustingtheMotion-ControlLinkage...............59

AdjustingtheMotion-ControlDamper...............60

AdjustingtheMotion-ControlNeutralLock

Pivot..............................................................60

HydraulicSystemMaintenance...........................61

ServicingtheHydraulicSystem........................61

MowerDeckMaintenance....................................63

LevelingtheMowerDeck..................................63

ServicingtheCuttingBlades.............................65

RemovingtheMowerDeck...............................68

ReplacingtheGrassDeector..........................69

Cleaning..............................................................70

CleaningundertheMower................................70

CleaningtheSuspensionSystem.....................70

DisposingofWaste...........................................70

Storage...................................................................71

CleaningandStorage.......................................71

Troubleshooting......................................................72

Schematics.............................................................75

3

Safety

Improperlyusingormaintainingthemachinecan
resultininjury.T oreducethepotentialforinjury,
complywiththesesafetyinstructionsandalways
payattentiontothesafetyalertsymbol,which
meansCaution,Warning,orDanger—personal
safetyinstruction.Failuretocomplywiththe
instructionmayresultinpersonalinjuryordeath.

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecycling
grassor,whenequippedwithagrassbagger,for
catchingcutgrass.Anyuseforpurposesother
thanthesecouldprovedangeroustotheuserand
bystanders.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI
B71.4-2012.

Training

•ReadtheOperator'sManualandothertraining

material.Iftheoperator(s)ormechanic(s)cannot
readorunderstandtheinformationitistheowner's
responsibilitytoexplainthismaterialtothem.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor

servicetheequipment.Localregulationsmay
restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtopeopleor
damagetoproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories

andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,

safetyglasses,andhearingprotection.Long
hair,looseclothing,orjewelrymaygettangledin
movingparts.

•Inspecttheareawheretheequipmentistobe

usedandremoveallobjectssuchasrocks,toys,
andwirewhichcanbethrownbythemachine.

•Checkthatoperator'spresencecontrols,safety

switches,andshieldsareattachedandfunctioning

properly.Donotoperateunlesstheyare
functioningproperly.

Operation

•Lightningcancausesevereinjuryordeath.If

lightningisseenorthunderisheardinthearea,do
notoperatethemachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfrom

holesandhiddenhazards.

•Besurealldrivesareinneutralandparkingbrake

isengagedbeforestartingtheengine.Onlystart
theenginefromtheoperator'sposition.

•Besureofyourtractionwhileusingthismachine,

especiallywhenbackingup.Neveroperateonwet
grass.Reducedtractioncouldcauseslipping.

•Slowdownanduseextracareonhillsides.Be

suretotravelsidetosideonhillsides.Turf
conditionscanaffectthestabilityofthemachine.
Usecautionwhileoperatingneardrop-offs.

•Slowdownandusecautionwhenmakingturns

andwhenchangingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshieldorotherguards

notsecurelyinplace.Besureallinterlocksare
attached,adjustedproperly,andfunctioning
properly.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor

overspeedtheengine.

•Stoponlevelground,disengagedrives,engage

theparkingbrake(ifprovided),andshutoffthe
enginebeforeleavingtheoperator'spositionfor
anyreason,includingemptyingthecatchersor
uncloggingthechute.

•Stopequipmentandinspectbladesafterstriking

objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobe

sureofaclearpath.

•Nevercarrypassengersonthemachine.

•Keeppetsandbystandersaway .

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalks.Stopblades
ifnotmowing.

•Beawareofthemowerdischargedirectionand

donotpointitatanyone.

•Donotoperatethemowerundertheinuenceof

alcoholordrugs.

4

•Usecarewhenloadingorunloadingthemachine

intoorfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

RolloverProtectionSystem (ROPS)—UseandMaintenance

•TheROPSisanintegralandeffectivesafety

device.KeepafoldingROPSintheraised
andlockedpositionandusetheseatbeltwhen
operatingthemachine.

•LowerafoldingROPStemporarilyonlywhen

absolutelynecessary.Donotweartheseatbelt
whenfoldeddown.

•Beawarethereisnorolloverprotectionwhena

foldedROPSisinthedownposition.

•Becertainthattheseatbeltcanbereleased

quicklyintheeventofanemergency.

•Checktheareatobemowedandneverfolddown

afoldingROPSinareaswherethereareslopes,
dropoffsorwater.

•Checkcarefullyforoverheadclearances(i.e.

branches,doorways,electricalwires)before
drivingunderanyobjectsanddonotcontactthem.

•KeeptheROPSinsafeoperatingconditionby

periodicallythoroughlyinspectingfordamageand
keepingallmountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairor

revise.

•DonotremovetheROPS.

•AnyalterationstoaROPSmustbeapprovedby

themanufacturer.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineis
extremelyammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlightsuchas
onawaterheateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruck

ortrailerbedwithaplasticliner.Alwaysplace
containersonthegroundawayfromyourvehicle
beforelling.

•Removeequipmentfromthetruckortrailerand

refuelitontheground.Ifthisisnotpossible,then
refuelsuchequipmentwithaportablecontainer,
ratherthanfromafueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefuel

tankorcontaineropeningatalltimesuntilfueling
iscomplete.

•Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothing

immediately.

•Neveroverllfueltank.Replacefuelcapand

tightensecurely.

MaintenanceandStorage

•Disengagedrives,settheparkingbrake,stop

theengineandremovethekeyordisconnect
thespark-plugwire.Waitforallmovementto
stopbeforeadjusting,cleaningorrepairingthe
machine.

•Cleangrassanddebrisfromthecuttingunit,the

drives,themufers,andtheenginetohelpprevent
res.Cleanupoilorfuelspillage.

•Lettheenginecoolbeforestoringanddonotstore

nearame.

•Shutoffthefuelwhilestoringortransporting.Do

notstorefuelnearamesordrainindoors.

•Parkthemachineonlevelground.Settheparking

brake.Neverallowuntrainedpersonneltoservice
themachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectthebatteryorthespark-plugwire

beforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositivelast.
Connectthepositiverstandnegativelast.

•Usecarewhencheckingtheblades.Wrapthe

blade(s)orwearthickly-paddedgloves,anduse
cautionwhenservicingthem.Onlyreplaceblades.
Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If

possible,donotmakeadjustmentswiththeengine
running.

•Keepallpartsingoodworkingconditionandall

hardwaretightened.Replaceallwornordamaged
decals.

•Tobestprotectyourinvestmentandmaintain

optimalperformanceofyourToroequipment,count
onT orogenuineparts.Whenitcomestoreliability,
Torodeliversreplacementpartsdesignedtothe
exactengineeringspecicationsofourequipment.
Forpeaceofmind,insistonT orogenuineparts.

5

Hauling

•Usecarewhenloadingorunloadingthemachine

intoatrailerortruck.

•Usefullwidthrampsforloadingthemachineintoa

trailerortruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps
shouldbedirecteddownandoutwardfromthe
machine.

6

SlopeIndicator

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

7

g011841

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedorlost.

58-6520

1.Grease

93-7818

decal58-6520

decal106-2655

106-2655

1.Warning-donottouchorapproachmovingbelts;remove
theignitionkeyandreadtheinstructionsbeforeservicing
orperformingmaintenance.

decal93-7818

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

99-8936

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

decal106-5517

106-5517

1.Warning—donottouchthehotsurface.

decal99-8936

8

decal107-3069

107-3069

1.Warning-thereisnorolloverprotectionwhentherollbaris
down.

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

3.ReadtheOperator’smanual;driveslowlyandcarefully.

decal110-2068

110-2068

1.ReadtheOperator'sManual.

decal112-9028

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin
place.

decal114-4466

114-4466

1.Main,25A

2.PTO,10A

3.Charge,25A

4.Auxiliary,15A

decal110-2067

110-2067

decal115-7445

115-7445

1.Greasepulleysandspindles

2.Maintenanceinterval—50hours

9

decal115-9625

115-9625

1.Parking

2.Parkingbrake—engaged

brake—disengaged

116-1716

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresenceswitch

decal116-1716

decal117-0346

117-0346

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

116-4858

116-8726

1.ReadtheOperator’sManualforrecommendedhydrooil.

decal116-4858

117-3848

decal117-3848

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine

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

3.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts;keepallguardsandshieldsinplace.

decal116-8726

10

decal117-3864

117-3864

1.ReadtheOperator’s

Manual.

1.Fast

2.Variablespeedcontrol

2.Filltobottomofllerneck;
warning—donotoverll
thetank.

121–7586

3.Slow

4.Powertake-off(PTO)

126-2055

decal126-4398

126-4398

1.ReadtheOperator’s

manual

2.Lock

decal121-7586

decal126-2055

3.Unlock

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

2.Wheelhubnuttorque235ft-lb(319N-m)

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

1.ReadtheOperator's

2.Height-of-cut

Manual.

decal127-0326

127-0326

3.Removethekeyfrom
theignitionandreadthe
Operator'sManualbefore
performingmaintenance
orservicingthemachine.

11

BatterySymbols

Someorallofthesesymbolsareonyourbattery

decaloemmarkt

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

decalbatterysymbols

1.Explosionhazard

2.Nore,opename,or

6.Keepbystandersasafe

7.Weareyeprotection;

smoking.

3.Causticliquid/chemical

8.Batteryacidcancause

burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

10.Containslead;donot

Manual.

distancefromthebattery.

explosivegasescan
causeblindnessandother
injuries

blindnessorsevereburns.

withwaterandgetmedical
helpfast.

discard.

125–9383

1.Checkhydraulicoilevery50operatinghours.3.Checkthetirepressureevery50operatinghours.

2.ReadtheOperator’sManualforinformationonlubricating
themachine.

4.ReadtheOperator’sManualbeforeservicingorperforming
maintenance.

12

decal125-9383

132-5063

1.Camlock2.Camunlock

decal132-5063

decal132-5067

132–5067

13

132-0871

Note:Thismachinecomplieswiththeindustrystandardstabilitytestinthestaticlateralandlongitudinaltestswiththemaximum

recommendedslopeindicatedonthedecal.ReviewtheinstructionsforoperatingthemachineonslopesintheOperator’sManualas
wellastheconditionsinwhichyouwouldoperatethemachinetodeterminewhetheryoucanoperatethemachineinthoseconditions
onthatdayandatthatsite.Changesintheterraincanresultinachangeinslopeoperationforthemachine.Ifpossible,keepthe
cuttingunitsloweredtothegroundwhileoperatingthemachineonslopes.Raisingthecuttingunitswhileoperatingonslopescan
causethemachinetobecomeunstable.

decal132-0871

1.Warning—readtheOperator’sManual;donotoperatethis
machineunlessyouaretrained;wearhearingprotection.

2.Cutting,dismembering,andentanglementhazard—keep
handsawayfrommovingparts;keepallguardsandshieldsin
place.

3.Thrownobjecthazard—keepbystandersaway.6.Tippinghazardonslopes—donotuseonslopesnearopen

4.Ramphazard—whenloadingontoatrailer ,donotusedual
ramps;onlyuseasingularrampwideenoughforthemachine
andthathasaninclinelessthan15°;backuptheramp(in
reverse)anddriveforwardofftheramp.

5.Bodilyharmhazard—donotcarrypassengers;lookbehind
youwhenmowinginreverse.

water;donotuseonslopesgreaterthan15°.

14

ProductOverview

g013112

Figure5

Figure4

1.Side-dischargedeector

2.Height-of-cutdeck-lift
pedal

3.Parking-brakelever10.Fuelcap

4.Transportlock11.Mowerdeck

5.Controls12.Casterwheel

6.Motion-controllevers13.Front,shockassembly

7.Rollbar

8.Rear,shockassembly

9.Seatbelt

Controls

Becomefamiliarwithallthecontrolsbeforeyoustart
theengineandoperatethemachine(Figure4and

Figure5).

1.PTOSwitch

g029631

2.Throttlecontrol5.Ignitionswitch

3.Malfunctionindicatorlight
(MIL)

4.Hour
meter/Safety-interlock
display/Fuelgauge

6.Fuses

FuelGauge

Thefuelgaugeislocatedwiththehourmeter,andthe
barslightupwhentheignitionswitchison(Figure6).

Theindicatorlightappearswhenthefuellevelis
low—approximately3.8L(1USgallon)remainingin
thefueltank.

Figure6

1.Fuelgauge(bars)4.Safety-interlocksymbols

2.Batterylight

3.Hourmeter

5.Low-fuelindicatorlight

HourMeter

Thehourmeterrecordsthenumberofhoursthe
enginehasoperated.Itoperateswhentheengine
isrunning.Usethesetimesforschedulingregular
maintenance(Figure5).

15

g008950

Safety-InterlockIndicators

Therearesymbolsonthehourmeterindicatewitha
blacktrianglethattheinterlockcomponentisinthe
correctposition(Figure6).

BatteryIndicatorLight

WhentheignitionkeyisinitiallyturnedtotheRun
positionforafewseconds,thebatteryvoltagewillbe
displayedintheareawherethehoursarenormally
displayed.

Thebatterylightturnsonwhentheignitionisturned
onandwhenthechargeisbelowthecorrectoperating
level(Figure6).

ThrottleControl

ThethrottlecontrolisvariablebetweenFastand
Slow.

Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)isusedtoengage
theelectricclutchanddrivethemowerblades.Pull
theswitchuptoengagethebladesandrelease.T o
disengagetheblades,pushtheblade-controlswitch
(PTO)downormoveamotion-controlleverintothe
neutrallockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas
threepositions:Start,RunandOff.

Motion-ControlLevers

Themotion-controlleversareusedtodrivethe
machineforward,reverse,andturneitherdirection.

Ifthesystemdetectsaproblemorfault,the
malfunctionindicatorlight(MIL)illuminates.

TheMIListheredlightlocatedintherightconsole
panel.

IftheMILilluminates,performtheinitial
troubleshootingchecks;refertotheMILsectionin

Troubleshooting(page72).

Ifthesechecksdonotcorrecttheproblem,further
diagnosisandservicingbyanAuthorizedService
Dealerisnecessary.

Attachments/Accessories

AselectionofT oroapprovedattachmentsand
accessoriesisavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.T oro.comforalistofallapprovedattachments
andaccessories.

Specications

Note:Specicationsanddesignaresubjectto

changewithoutnotice.

Width:

60-inchDeck

WithoutDeck

DeectorUp156.8cm(61.7inches)

DeectorDown192.2cm(75.7inches)

Length:

RollBar—Up

RollBar—Down

134.6cm(53.0inches)

60-inchDeck

211.1cm(83.1inches)

215.4cm(84.8inches)

Neutral-LockPosition

Theneutral-lockpositionisusedwiththe
safety-interlocksystemandtodeterminetheneutral
position.

Fuel-ShutoffValve

Closethefuel-shutoffvalve(undertheseat)when
transportingorstoringthemower.

ElectronicControlUnit
MalfunctionIndicatorLight

Theelectroniccontrolunit(ECU)continuously
monitorstheoperationoftheEFIsystem.

Height:

RollBar—UpRollBar—Down

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

Weight:

ModelWeight

74991

16

587kg(1295lbs)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane
ratingof87orhigher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl
ether)byvolumeisacceptable.Ethanoland
MTBEarenotthesame.Gasolinewith15%
ethanol(E15)byvolumeisnotapprovedforuse.
Neverusegasolinethatcontainsmorethan10%
ethanolbyvolume,suchasE15(contains15%
ethanol),E20(contains20%ethanol),orE85
(containsupto85%ethanol).Usingunapproved
gasolinemaycauseperformanceproblemsand/or
enginedamagewhichmaynotbecoveredunder
warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessafuelstabilizer
isused.

•Donotaddoiltogasoline.

DANGER

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

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis6
to13mm(1/4to1/2inch)belowthebottom
ofthellerneck.Thisemptyspaceinthe
tankallowsgasolinetoexpand.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainer
andkeepitoutofthereachofchildren.
Neverbuymorethana30-daysupplyof
gasoline.

•Donotoperatewithouttheentireexhaust
systeminplaceandinproperworking
condition.

DANGER

Incertainconditionsduringfueling,static
electricitycancauseasparkwhichcanignite
thegasolinevapors.Areorexplosionfrom
gasolinecanburnyouandothersandcan
damageproperty.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebefore
lling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbed,because
interiorcarpetsorplastictruck-bedliners
mayinsulatethecontainerandslowthe
lossofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
fueltheequipmentwiththewheelsonthe
ground.

Ifthisisnotpossible,thenfuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasoline-dispensernozzle.

•Ifagasolinedispensermustbeused,keep
thenozzleincontactwiththerimofthe
fueltankorcontaineropeningatalltimes
untilfuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancause
seriousinjuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastank
orconditionerbottleopening.

•Avoidcontactwithskin;washoffspillage
withsoapandwater.

UsingFuelStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
keepthefuelfreshduringstorageof90daysorless.
Ifyouarestoringthemachineforlonger,drainthefuel
tank;refertoStorage(page71).

Important:Donotusefueladditivescontaining

methanolorethanol.

Addthecorrectamountoffuelstabilizer/conditionerto
thefuel,andfollowthedirectionsofthemanufacturer.

Note:Fuelstabilizer/conditionerismosteffective

whenmixedwithfreshgasoline.T ominimizethe

17

chanceofvarnishdepositsinthefuelsystem,usefuel
stabilizeratalltimes.

FillingtheFuelTank

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefuel-tankcapandremoveit.
Addregularunleadedgasolinetothefueltank
untilthelevelis6to13mm(1/4to1/2inch)
belowthebottomofthellerneck.Thisextra
spaceinthetankallowsthegasolinetoexpand.
Donotllthefueltankcompletelyfull;referto
(Figure7).

g029938

g027726

Figure7

18

CheckingtheEngine-Oil Level

Beforeyoustarttheengineandusethemachine,
checktheoillevelintheenginecrankcase;referto

CheckingtheEngine-OilLevel(page40).

BreakinginaNewMachine

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

UsingtheRollover ProtectionSystem(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keep
therollbarinthefullyraisedlockedposition
andusetheseatbelt.

Ensurethattherearpartoftheseatissecured
withtheseatlatch.

WARNING

Thereisnorolloverprotectionwhentheroll
barisinthedownposition.

•Lowertherollbaronlywhenabsolutely
necessary.

•Donotweartheseatbeltwhentherollbar
isinthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearance
permits.

•Checkcarefullyforoverheadclearances
(i.e.branches,doorways,electricalwires)
beforedrivingunderanyobjectsanddo
notcontactthem.

Important:Lowertherollbaronlywhen

absolutelynecessary.

Figure8

1.ROPSknob

2.PullROPSknoboutand
rotate90degrees

4.Toraisetherollbar,raisetherollbartothe

operateposition,rotatetheknobssothatthey
movepartiallyintothegrooves(Figure8).

5.Raisetherollbartothefulluprightpositionwhile

pushingontheupperrollbarandthepinswill
snapintopositionwhentheholesalignwiththe
pins(Figure8).Pushontherollbarandensure
thatbothpinsareengaged.

3.Rollbarintheupright
position

4.Rollbarinthefolded
position

Important:Alwaysusetheseatbeltwiththe

rollbarinthefullyraisedposition.

g008943

1.Tolowertherollbar,applyforwardpressureto
theupperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sothat
theyarenotengaged(Figure8).

3.Lowertherollbartothedownposition(Figure

8).

EnteringtheUserPosition

Usethemowerdeckasasteptogetintotheuser
position(Figure9).

19

Figure9

1.Mowerdeck

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe
safetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.

g029797

Figure10

1.SafeZone-usethe
ZMasterhereonslopes
lessthan15degreesor
atareas.

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

3.Water

g000963

DANGER

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.

Wheelsdroppingoveredgescancause
rollovers,whichmayresultinseriousinjury,
death,ordrowning.

Thereisnorolloverprotectionwhentheroll
barisdown.

Alwayskeeptherollbarinthefullyraisedand
lockedpositionandusetheseatbelt.

Readandfollowtherolloverprotection
instructionsandwarnings.

Toavoidlossofcontrolandpossibilityof
rollover:

•Donotoperateneardrop-offsornear
water.

•Donotoperateonslopesgreaterthan
15degrees.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,feet,
andheadisrecommended.

Figure11

1.Wearsafetyglasses

2.Wearhearingprotection

g009027

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeed
changes.

OperatingtheParking Brake

Alwayssettheparkingbrakewhenyoustopthe
machineorleaveitunattended.

20

SettingtheParkingBrake

WARNING

Theparkingbrakemaynotholdmachine
parkedonaslopeandcouldcausepersonal
injuryorpropertydamage.

Donotparkonslopesunlessthewheelsare
chockedorblocked.

Figure12

ReleasingtheParkingBrake

g008945

Figure14

DisengagingtheBlade-Control Switch(PTO)

g029632

g009174

Figure15

OperatingtheThrottle

ThethrottlecontrolcanbemovedbetweenFastand
Slowpositions(Figure16).

Figure13

OperatingtheMower Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)startsandstopsthe
mowerbladesandanypoweredattachments.

EngagingtheBlade-Control Switch(PTO)

Note:Engagingtheblade-controlswitch(PTO)with

thethrottlepositionathalforlesswillcauseexcessive
weartothedrivebelts.

Alwaysusethefastpositionwhenturningonthe
mowerdeckwiththeblade-controlswitch(PTO).

g029829

g008946

Figure16

OperatingtheIgnition Switch

1.TurntheignitionkeytotheStartposition(Figure

17).Whentheenginestarts,releasethekey.

Important:Donotengagethestarterfor

morethan5secondsatatime.Iftheengine
failstostart,allowa15secondcool-down

21

periodbetweenattempts.Failuretofollow
theseinstructionscanburnoutthestarter
motor.

Note:Additionalstartingcyclesmaybe

requiredwhenstartingtheenginefortherst
timeafterthefuelsystemhasbeencompletely
withoutfuel.

Figure17

2.Tostoptheengine,turntheignitionkeytothe
stopposition.

StartingandStoppingthe Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,siton
theseatandfastentheseatbelt.

2.Movethemotioncontrolstoneutral-locked
position.

3.Settheparkingbrake;refertoSettingthe
ParkingBrake.

4.Movetheblade-controlswitch(PTO)totheOff
position(Figure19).

5.Movethethrottlelevermidwaybetweenthe

g008947

SlowandFastpositions.

UsingtheFuel-Shutoff Valve

Thefuel-shutoffvalveislocatedundertheseat.Move
theseatforwardtoaccessit.

Closethefuel-shutoffvalvefortransport,maintenance,
andstorage.

Ensurethatthefuel-shutoffvalveisopenwhen
startingtheengine.

g029634

Figure19

6.TurntheignitionkeytotheStartposition(Figure

17).Whentheenginestarts,releasethekey.

Figure18

1.On2.Off

g008948

22

StoppingtheEngine

TheSafety-Interlock

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60
secondsbeforeturningtheignitionswitchoff.

System

CAUTION

Ifsafety-interlockswitchesaredisconnected
ordamagedthemachinecouldoperate
unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

Understandingthe Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe
enginefromstartingunless:

•Theparkingbrakeisengaged.

•Theblade-controlswitch(PTO)isdisengaged.

•Themotion-controlleversareintheneutral-locked

position

Figure20

Important:Makesurethatthefuelshutoff

valveisclosedbeforetransportingorstoring
themachine,asfuelleakagemayoccur.Setthe
parkingbrakebeforetransporting.Makesureto
removethekeyasthefuelpumpmayrunand
causethebatterytolosecharge.

Thesafety-interlocksystemalsoisdesignedtostop
theenginewhenthetractioncontrolsaremovedfrom
thelockedpositionwiththeparkingbrakeengagedor
ifyourisefromtheseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhen
theinterlockcomponentisinthecorrectposition.
Whenthecomponentisinthecorrectposition,a
trianglewilllightupinthecorrespondingsquare.

g029635

g009181

Figure21

1.Triangleslightupwhentheinterlockcomponentsareinthe
correctposition

TestingtheSafety-Interlock System

ServiceInterval:Beforeeachuseordaily

23

Testthesafety-interlocksystembeforeyouusethe
machineeachtime.Ifthesafetysystemdoesnot
operateasdescribedbelow,haveanAuthorized
ServiceDealerrepairthesafetysystemimmediately .

1.Sittingontheseat,engagetheparkingbrake
andmovetheblade-controlswitch(PTO)toon.
Trystartingtheengine;theengineshouldnot
crank.

2.Sittingontheseat,engagetheparkingbrake
andmovetheblade-controlswitch(PTO)to
off.Moveeithermotion-controllever(outof
neutral-lockedposition).Trystartingtheengine;
theengineshouldnotcrank.Repeatforother
controllever.

3.Sittingontheseat,engagetheparkingbrake,
movetheblade-controlswitch(PTO)tooffand
movethemotion-controlleverstoneutrallock
position.Nowstarttheengine.Whiletheengine
isrunning,releasetheparkingbrake,engage
theblade-controlswitch(PTO)andriseslightly
fromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,
movetheblade-controlswitch(PTO)tooffand
movethemotion-controlleverstoneutrallock
position.Nowstarttheengine.Whiletheengine
isrunning,centereithermotioncontroland
move(forwardorreverse);theengineshould
stop.Repeatforothermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake,
movetheblade-controlswitch(PTO)tooffand
movethemotion-controlleverstoneutrallock
position.Trystartingtheengine;theengine
shouldnotcrank.

UsingtheMotion-ControlLevers

Figure22

1.motion-control
lever—neutral-lock
position

2.Center,unlockedposition5.Frontofmachine

3.Forward

g004532

4.Backward

DrivingForwardor Backward

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

CAUTION

Machinecanspinveryrapidly.Operatormay
losecontrolofmachineandcausepersonal
injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

DrivingForward

Note:Theenginewillkillifthetractioncontrollevers

aremovedwiththeparkingbrakeengaged.

Tostop,pullthemotion-controlleverstotheneutral
position.

1.Releasetheparkingbrake;refertoReleasing
theParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotion-control
leversforward(Figure23).

24

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers
toneutralandtothelockedposition,disengagethe
powertake-off(blade-controlswitch(PTO),andturn
theignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;
refertoSettingtheParkingBrakeinOperation.
Remembertoremovethekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

Figure23

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,lookbehindandslowlypullthe
motion-controlleversrearward(Figure24).

g008952

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhas2positionsandisusedwiththe
deckliftpedal.Thereisalockpositionandanunlock
positionforthetransportposition.Thetransportlock
isusedwiththedeckliftpedal.RefertoFigure25

Figure24

g008953

25

AdjustingtheHeight-of-CutPin

Theheightofcutisadjustedfrom25to140mm(1to
5-1/2inches)in6mm(1/4inch)incrementsbymoving
theclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfoot,and
raisethemowerdecktothetransportposition
(alsothe140mm(5-1/2inch)cutting-height
position);refertoFigure26.

3.Toadjust,rotatethepin90degreesandremove
thepinfromtheheight-of-cutbracket(Figure

26).

4.Selectaholeintheheight-of-cutbracket
correspondingtotheheightofcutdesired,and
insertthepin(Figure26).

5.Pushonthedecklift,pullbackonthetransport
lock,andslowlylowerthemowerdeck.

Figure25

Transportlockpositions

1.Transportlock3.Unlockposition—doesnot
lockthemowerdeckinto
transportposition

2.Lockposition—mower

deckwilllockintotransport
position

g008955

26

Figure28

g029956

Figure26

1.Deckliftpedal

2.Height-of-cutpin

3.Transportlock

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheightofcut,itis
recommendedtoadjusttheheightoftheanti-scalp
rollers.

1.Disengagetheblade-controlswitch(PTO),move

themotion-controlleverstotheneutral-locked
position,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait

forallmovingpartstostopbeforeleavingthe
operatingposition.

g029840

1.Anti-scalproller3.Flangenut

2.Bushing4.Bolt

Figure29

1.Anti-scalproller4.Flangenut

2.Spacer

3.Bushing

5.Bolt

g029957

Figure27

1.Anti-scalproller4.Flangenut

2.Spacer

3.Bushing

5.Bolt

AdjustingtheFlowBafe
CamLocks

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

g029955

Themowerdischargeowcanbeadjustedfor
differenttypesofmowingconditions.Positionthecam
locksandbafetogivethebestqualityofcut.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Toadjustthecamlocks,swingtheleverupto
loosenthecamlock(Figure30).

27

4.Adjustthebafeandcamlocksintheslotsto
thedesireddischargeow.

5.Swingtheleverbackovertotightenthebafe
andcamlocks(Figure30).

6.Ifthecamlocksdonotlockthebafeintoplace
oritistootight,loosentheleverandthenrotate
thecamlock.Adjustthecamlockuntilthe
desiredlockingpressureisachieved.

Figure30

PositionB

Usethispositionwhenbagging.Alwaysalignitwith
thebloweropening.

g005833

Figure32

g027727

PositioningtheFlowBafe

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

Note:Iftheenginepowerdrawsdownandthe

mowergroundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggestedusefor
thispositionisasfollows.

•Useforshort,lightgrass-mowingconditions.

•Useindryconditions.

•Forsmallergrassclippings.

•Propelsgrassclippingsfartherawayfromthe

mower.

PositionC

Thisisthefullopenposition.Thesuggestedusefor
thispositionisasfollows.

•Useintall,densegrass-mowingconditions.

•Useinwetconditions.

•Lowerstheenginepowerconsumption.

•Allowsincreasedgroundspeedinheavy

conditions.

•ThispositionissimilartothebenetsoftheToro

SFSmower.

Figure31

g005834

Figure33

g005832

28

PositioningtheSeat

Theseatcanmoveforwardandbackward.Position
theseatwhereyouhavethebestcontrolofthe
machineandaremostcomfortable.

2shockassembliesistheeasiestandquickest
adjustmentforchangingthesuspensionsystem.
Positionthesuspensionsystemwhereyouaremost
comfortable.

Toadjusttheseat,movetheleversidewaystounlock
seatandthenmovetheseatforwardorbackward
(Figure34).

Figure34

UnlatchingtheSeat

AdjustingtheRear,Shock Assemblies

Theslotsfortherear,shockassemblieshavedetent
positionsforreference.Therear,shockassemblies
canbepositionedanywhereintheslot,notjustthe
detentpositions.

Thefollowinggraphicshowsthepositionforasoftor
rmrideandthedifferentdetentpositions(Figure36).

g029830

AdjustingtheMyRide™

g030065

Figure36

1.Firmestposition3.Detentsintheslots

2.Softestposition

Note:Ensuretheleftandrightrear,shockassemblies

arealwaysadjustedtothesamepositions.

g030021

Figure35

SuspensionSystem

TheMyRide™suspensionsystemadjuststoprovide
asmoothandcomfortableride.Adjustingtherear

29

Adjusttherear,shockassemblies(Figure37).

Toadjustthefront,shockassembly ,opentheoor
panandadjustitbyusingaspannerwrench(Toro
partno.132–5069)oraslip-jointpliers(Figure38).

g030024

g030049

Figure38

1.Middleposition

2.Firmride

3.Softride

UsingtheDriveWheel ReleaseValves

WARNING

Handsmaybecomeentangledintherotating
drivecomponentsbelowtheenginedeck,
whichcouldresultinseriousinjury.

Stoptheengine,removethekey,andallow
allmovingpartstostopbeforeaccessingthe
drivewheelreleasevalves.

WARNING

Theengineandhydraulicdriveunitscan
becomeveryhot.Touchingahotengineor
hydraulicdriveunitscancausesevereburns.

Figure37

AdjustingtheFront,Shock Assembly

Thefront,shockassemblyissetatthemiddleposition
andisnormallynotadjusted.

Allowtheengineandhydraulicdriveunitsto
coolcompletelybeforeaccessingthedrive

g030019

wheelreleasevalves.

Thedrivewheelreleasevalvesarelocatedintheback
ofeachhydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefully

horizontalpositionwhenoperatingthemachineor
severedamagetothehydraulicsystemcanoccur.

1.DisengagethePTO(blade-controlswitch)and
turntheignitionkeytooff.Movetheleversto

30

neutral-lockedpositionandapplyparkingbrake.
Removethekey.

2.Rotatethereleasevalveleversverticallytopush
themachine.Thisallowshydraulicoiltoby-pass
thepumpenablingthewheelstoturn(Figure

39).

3.Disengageparkingbrakebeforepushing.

Figure39

1.Verticaltopushthe

machine

2.Horizontaltorunthe
machine

DANGER

Withoutagrassdeector,dischargecover,or
completegrasscatcherassemblymountedin
place,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebris
willcauseinjuryordeath.

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

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(blade-controlswitch(PTO)tothe
offposition,rotatetheignitionkeytooff

g029831

andremovethekey .

•Makesurethegrassdeectorisinthe
downposition.

4.Rotatethereleasevalvelevershorizontallyto
runthemachine(Figure39).

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthat
dispersesclippingstothesideanddowntowardthe
turf.

31

TransportingtheMachine

LoadingtheMachine

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall
necessarybrakes,lighting,andmarkingasrequired
bylaw.Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily,
pets,orbystandersavoidinjury.

WARNING

Drivingonthestreetorroadwaywithout
turnsignals,lights,reectivemarkings,ora
slow-movingvehicleemblemisdangerous
andcanleadtoaccidentscausingpersonal
injury.

Donotdrivethemachineonapublicstreet
orroadway.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle
andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,
andclosethefuelvalve.

5.Usethemetaltie-downloopsonthemachineto
securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes(Figure40).

Useextremecautionwhenloadingorunloading
machinesontoatraileroratruck.Useafull-width
rampthatiswiderthanthemachineforthisprocedure.
Backuprampsanddriveforwarddownramps(Figure

41).

Figure41

1.Backupramps

2.Driveforwarddownramps

Important:Donotusenarrowindividualramps

foreachsideofthemachine.

Ensuretherampislongenoughsothattheanglewith
thegrounddoesnotexceed15degrees(Figure42).
Onatground,thisrequiresaramptobeatleastfour
times(4X)aslongastheheightofthetrailerortruck
bedtotheground.Asteeperanglemaycausemower
componentstogetcaughtastheunitmovesfromthe
ramptothetrailerortruck.Steeperanglesmayalso
causethemachinetotiporlosecontrol.Ifloadingon
ornearaslope,positionthetrailerortrucksothatitis
onthedownsideoftheslopeandtherampextends
uptheslope.Thiswillminimizetherampangle.

g028043

1.Tie-downloops

g029641

Figure40

32

WARNING

Loadingamachineontoatrailerortruck
increasesthepossibilityoftip-overandcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga
machineonaramp.

•EnsurethattheROPSisintheupposition
andusetheseatbeltwhenloadingor
unloadingthemachine.Ensurethatthe
ROPSwillclearthetopofanenclosed
trailer.

•Useonlyafull-widthramp;donotuse
individualrampsforeachsideofthe
machine.

•Donotexceeda15-degreeanglebetween
therampandthegroundorbetweenthe
rampandthetrailerortruck.

•Ensurethelengthoframpisatleastfour
times(4X)aslongastheheightofthe
trailerortruckbedtotheground.Thiswill
ensurethatrampangledoesnotexceed15
degreesonatground.

•Backuprampsanddriveforwarddown
ramps.

•Avoidsuddenaccelerationordeceleration
whiledrivingthemachineonarampas
thiscouldcausealossofcontrolora
tip-oversituation.

1.Full-widthrampinstowed
position

2.Sideviewoffull-width
rampinloadingposition

3.Notgreaterthan
15degrees

g027996

Figure42

4.Rampisatleastfourtimes
(4X)aslongastheheight
ofthetrailerortruckbed
totheground

5.H=heightofthetraileror
truckbedtotheground

6.Trailer

33

OperatingTips

FastThrottleSetting

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

CuttingaLawnfortheFirstTime

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan
normal,orifitcontainsahighdegreeofmoisture,
raisethecuttingheighthigherthanusualandcutthe
grassatthissetting.Thencutthegrassagainusing
thelower,normalsetting.

WhenStopping

Ifyoumuststoptheforwardmotionofthemachine
whilemowing,aclumpofgrassclippingsmaydrop
ontoyourlawn.T oavoidthis,moveontoapreviously
cutareawiththebladesengaged.

Cutgrassslightlylongerthannormaltoensurethe
cuttingheightofthemowerdoesnotscalpanyuneven
ground.However,thecuttingheightusedinthepast
isgenerallythebestonetouse.Whencuttinggrass
longerthansixinchestall,youmaywanttocutthe
lawntwicetoensureanacceptablequalityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.
Cuttingmorethanthatisnotrecommendedunless
grassissparse,oritislatefallwhengrassgrows
moreslowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding
straight.Thisalsohelpsdisperseclippingswhich
enhancesdecompositionandfertilization.

MowatCorrectIntervals

Normally,moweveryfourdays.Butremember,
grassgrowsatdifferentratesatdifferenttimes.So
tomaintainthesamecuttingheight,whichisagood
practice,mowmoreofteninearlyspring.Asthe
grassgrowthrateslowsinmidsummer,mowless
frequently.Ifyoucannotmowforanextendedperiod,
rstmowatahighcuttingheight;thenmowagaintwo
dayslateratalowerheightsetting.

KeeptheUndersideoftheMower
Clean

Cleanclippingsanddirtfromtheundersideofthe
moweraftereachuse.Ifgrassanddirtbuildupinside
themower,cuttingqualitywilleventuallybecome
unsatisfactory.

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseason
becauseasharpbladecutscleanlywithouttearingor
shreddingthegrassblades.T earingandshredding
turnsgrassbrownattheedges,whichslowsgrowth
andincreasesthechanceofdisease.Checkthe
cutterbladesdailyforsharpness,andforanywearor
damage.Filedownanynicksandsharpentheblades
asnecessary.Ifabladeisdamagedorworn,replaceit
immediatelywithagenuineTOROreplacementblade.

CuttingSpeed

Toimprovecutquality,useaslowergroundspeed
incertainconditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe
moweryoupreviouslyused,raisethecuttingheightto
ensurethatuneventurfisnotcuttooshort.

34

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst100hours

Aftertherst250hours

Beforeeachuseordaily

Every50hours

Every100hours

Every150hours

MaintenanceProcedure

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Checktheparkingbrakeadjustment.

•Changethehydraulicltersandhydraulicoilwhenusinganytypeofoil.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunitshrouds.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil(moreoftenindirtyordustyconditions).

•Checkandcleanenginecoolingnsandshrouds.

•Inspecttheprimarylterandair-inletscreen.

Every200hours

Every250hours

Every300hours

Every500hours

Every600hours

Yearlyorbeforestorage

•Changetheengineoillter.

•Cleantheengineoilcooler.

•Checkandgapthesparkplug.

•Replacethefuellter(moreoftenindirtyordustyconditions).

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

•Replacetheprimaryairlter(moreoftenindustyorsandyconditions).

•Checktheinnerairlter.

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Adjustthecasterpivotbearing.

•Checktheparkingbrakeadjustment.

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

•Replacetheinnerairlter.

Monthly

Yearly

•Checkthebattery.

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs.

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

35

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

LubricatingtheMachine

Greasemorefrequentlywhenoperatingconditions
areextremelydustyorsandy.

GreaseType:No.2general-purposelithium-based
ormolybdenum-basedgrease

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

Figure44

g017050

3.Cleanthegreasettingswitharag.Makesure
toscrapeanypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pump
greaseintothettingsuntilgreasebeginsto
oozeoutofthebearings.

5.Wipeupanyexcessgrease.

AddingLightOilorSpray Lubrication

ServiceInterval:Every100hours

Lubricatethedeckliftpivots.

GreasingtheMower

ServiceInterval:Every50hours—Greasethemower

deckspindlesandidlerarm.

Yearly—Greasethepumpbeltidlerarm.

Yearly—Greasethefrontcasterpivots(more
oftenindirtyordustyconditions).

Yearly—Repackthefrontcasterwheelbearings
(moreoftenindirtyordustyconditions).

Important:Makesurethatthecuttingunit

spindlesarefullofgreaseweekly.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
position,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Greasethemowerdeckidlerpulleypivotuntil
greasecomeoutthebottom(Figure45).

4.Greasethe3spindlebearingsuntilgrease
comesoutthelowerseals(Figure45).

Figure43

g029642

36

Figure45

5.Greasethedrivebeltidlerarm(Figure45).

g029643

Figure47

g009029

Figure46

6.Removethedustcapandadjustthecaster
pivots.

Note:Keepthedustcapoffuntilgreasingis

complete.RefertoAdjustingtheCasterPivot

Bearing(page52).

7.Removethehexplugandthreadagreasetting
intothehole.

8.Pumpgreaseintothettinguntilitoozesout
aroundthetopbearing.

9.Removethegreasettingfromthehole.

10.Installthehexpluganddustcap(Figure47).

g009030

37

LubricatetheCasterWheel Hubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop,
andremovethekey.Engagetheparkingbrake.

11.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
general-purposegrease.

12.Insertthesecondbearingandnewsealintothe
wheel.

13.Applyathreadlockingadhesivetothesecond
spacernutandthreaditontotheaxlewiththe
wrenchatsfacingoutward.

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

Note:Makesurethattheaxledoesnotextend

beyondeithernut.

15.Installthesealguardsoverthewheelhuband
insertthewheelintothecasterfork.Installthe
casterboltandtightenthenutfully.

Figure48

1.Sealguard2.Spacernutwithwrench
ats

2.Raisethefrontofthemachineupandsupportit

withjackstands.

3.Removethecasterwheelfromthecasterforks.

4.Removethesealguardsfromthewheelhub.

5.Remove1ofthespacernutsfromtheaxle

assemblyinthecasterwheel.

Note:Notethatthreadlockingadhesivehas

beenappliedtolockthespacernutstotheaxle.
Removetheaxle(withtheotherspacernutstill
assembledtoit)fromthewheelassembly.

6.Pryouttheseals,andinspectthebearingsfor

wearordamageandreplaceifnecessary.

7.Packthebearingswithageneral-purpose

grease.

8.Insert1bearingand1newsealintothewheel.

g006115

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe
castertire.Thetireshouldnotspinfreely(more
than1or2revolutions)orhaveanysideplay.If
thewheelspinsfreely,adjustthetorqueonthe
spacernutuntilthereisaslightamountofdrag.
Applythreadlockingadhesive.

Note:Thesealsmustbereplaced.

9.Iftheaxleassemblyhashadbothspacernuts

removed(orbrokenloose),applyathread
lockingadhesiveto1spacernutandthread
itontotheaxlewiththewrenchatsfacing
outward.

Note:Donotthreadthespacernutallof

thewayontotheendoftheaxle.Leave
approximately3mm(1/8inch)fromtheouter
surfaceofthespacernuttotheendoftheaxle
insidethenut.

10.Inserttheassemblednutandaxleintothewheel
onthesideofthewheelwiththenewsealand
bearing.

38

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal
injury.

Keephands,feet,face,clothing,andother
bodypartsawaythemuferandotherhot
surfaces.

ServicingtheAirCleaner

ServiceInterval:Every150hours

Every300hours/Yearly(whichevercomes
rst)—Replacetheprimaryairlter(moreoften
industyorsandyconditions).

Every300hours—Checktheinnerairlter.

Every600hours—Replacetheinnerairlter.

Note:Checktheltersmorefrequentlyifthe

operatingconditionsareextremelydustyorsandy .

RemovingtheFilters

1.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedposition,andsetthe
parkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Releasethelatchesontheaircleanerand
pulltheair-inletcoverofftheair-cleanerbody
(Figure49).

4.Cleantheair-inletscreenandcover.

5.Installtheair-inletcoverandsecureitwiththe
latches(Figure49).

Figure49

1.Cover

2.Primarylter6.Cover

3.Innerlter

4.Air-cleanerbody

6.Releasethelatchesontheaircleanerandpull
theair-cleanercoverofftheair-cleanerbody
(Figure49).

7.Cleantheinsideoftheair-cleanercoverwith
compressedair.

8.Gentlyslidetheprimarylteroutofthe
air-cleanerbody(Figure49).

5.Air-inletscreen

7.Latch

Note:Avoidknockingthelterintothesideof

thebody.

9.Removetheinnerlteronlyifyouintendto
replaceit.

Important:Neverattempttocleanthe

innerlter.Ifthesafetylterisdirty,then
theprimarylterisdamaged;replaceboth
lters.

10.Inspecttheprimarylterfordamagebylooking
intothelterwhileshiningabrightlightonthe
outsideofthelter.

g030481

Note:Anyholesinthelterwillappearasbright

spots.Ifthelterisdamaged,discardit.

ServicingthePrimaryFilter

•Iftheprimarylterisdirty,bent,ordamaged,

replaceit.

•Donotcleantheprimarylter.

ServicingtheSafetyFilter

Replacethesafetylter,nevercleanit.

Important:Neverattempttocleanthesafety

lter.Ifthesafetylterisdirty ,thentheprimary
lterisdamaged.Replacebothlters.

39

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandcover
installed.

1.Ifinstallingnewlters,checkeachlterfor
shippingdamage.Donotuseadamagedlter.

2.Iftheinnerlterisbeingreplaced,carefullyslide
itintothelterbody(Figure49).

3.Carefullyslidetheprimarylterovertheinner
lter(Figure49).

Note:Ensurethattheprimarylterisfully

seatedbypushingonitsouterrimwhileinstalling
it.

Important:Donotpressonthesoftinside

areaofthelter.

4.Installtheaircleanercoverandsecurethe
latches(Figure49).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceclassSL,SM,

SN,orhigher)

OilCapacity:withalterchange,1.7L(1.8USqt);
withnolterchange,1.4L(1.5USqt)

Viscosity:Seethetablebelow.

g012991

Figure50

Note:Useofsyntheticoilhaving5W-20or5W-30

ratingisacceptable,upto4degreesC(40degreesF).

Note:Syntheticoilswillprovidebetterstartingin

extremecoldbelow-23degreesC(-10degreesF).

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal
injury.

Keephands,feet,face,clothingandother
bodypartsawayfromthemuferandother
hotsurfaces.

Important:Donotoverllthecrankcasewithoil

becausedamagetotheenginemayresult.Donot
runenginewithoilbelowthelowmarkbecause
theenginemaybedamaged.

1.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition(Figure51).

40

ChangingtheEngineOil

ServiceInterval:Every100hours(moreoftenindirty

ordustyconditions).

Note:Disposeoftheusedoilatarecyclingcenter.

g029644

1.Parkthemachinesothattherearisslightly
lowerthanthefronttoensurethattheoildrains
completely.

2.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedposition,andsetthe
parkingbrake.

3.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition(Figure52).

g029644

Figure51

g027659

g027734

Figure52

41

4.Slowlypourapproximately80%ofthespecied
oilintothellertubeandslowlyaddthe
additionaloiltobringittotheFullmark(Figure

53).

g029644

Figure53

5.Starttheengineanddrivetoaatarea.Check
theoillevelagain.

ChangingtheEngine-OilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequently

whenoperatingconditionsareextremelydustyor
sandy.

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page41).

2.Changetheengineoillter(Figure54).

g027660

g027477

Figure54

Note:Ensuretheoilltergaskettouchesthe

engineandthenanextra3/4turniscompleted.

3.Fillthecrankcasewiththepropertypeofnew
oil;refertoChangingtheEngineOil(page41).

ServicingtheEngine-OilCooler

ServiceInterval:Every200hours

1.Keeptheoilcoolerfreeofdebris.bycleaning
thenswithabrush.

2.Removetheboltsholdingtheoilcoolertothe
enginehousing.

3.Cleantheinsideoftheoilcoolerwithabrush.

4.Installtheoilcoolertotheenginehousing.

42

ServicingtheSparkPlugs

ServiceInterval:Every200hours—Checkandgap

thesparkplug.

Makesurethattheairgapbetweenthecenterand
sideelectrodesiscorrectbeforeinstallingthespark

g029644

plugs.Useaspark-plugwrenchforremovingand
installingthesparkplugsandagappingtool/feeler
gaugetocheckandadjusttheairgap.Installnew
sparkplugsifnecessary.

Figure55

1.Engineoilcooler2.Bolts

g013011

Type:Champion

®

XC12YC,Champion

®

Platinum

3071orequivalent

AirGap:0.76mm(0.030inch)

RemovingtheSparkPlugs

1.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

2.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedpositionandsetthe
parkingbrake.

3.Removetheleft-handhydraulicunitshroudin
theorderlistedwithFigure56.

Note:Thisgivesyouaccesstothefrontspark

plug.

43

CheckingtheSparkPlugs

Important:Replacethesparkplugswhenthey

have:ablackcoating,wornelectrodes,anoily
lm,cracksorreuseisquestionable.

Ifyouseelightbrownorgrayontheinsulator,the

g029645

engineisoperatingproperly.Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

Setthegapto0.76mm(0.030inch).

g027479

Figure58

InstallingtheSparkPlugs

1.Pullthistabouttothe
sideinthedirectionofthe
arrow.

2.Pulltheshroudoffofthis
frametabinthedirection
ofthearrow.

4.Removethesparkplugs.

Figure56

3.Pulltheshroudoffofthis
frametabinthedirection
ofthearrow.

4.Shroud

Tightenthesparkplugsto24.4to29.8N-m(18to

g009919

g029646

22ft.-lb).

g027735

Figure59

Figure57

5.Installthelefthandhydraulicunitshroud(Figure

56).

g027478

44

CheckSparkArrester(if

FuelSystem

equipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite
gasolinevaporsevenaftertheengineis
stopped.Hotparticlesexhaustedduring
engineoperationmayigniteammable
materials.Firemayresultinpersonalinjury
orpropertydamage.

Donotfuelorruntheengineunlessspark
arresterisinstalled.

1.Stopengine,waitforallmovingpartstostop,
andremovekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsare
observed,replacethearrester.

4.Ifpluggingofthescreenisobserved,remove
thearresterandshakelooseparticlesoutof
thearresterandcleanscreenwithawirebrush
(soakinsolventifnecessary).Reinstallarrester
onexhaustoutlet.

Maintenance

WARNING

Fuelsystemcomponentsareunderhigh
pressure.Theuseofimpropercomponents
canresultinsystemfailure,gasolineleakage,
andpossibleexplosion.

Useonlyapprovedfuellinesandfuellters.

ServicingtheElectronic FuelInjectionSystem

Thismachinecontainsanelectronicfuelinjection
system.Itcontrolsthefuelowunderdifferent
operatingconditions.

Theelectroniccontrolunit(ECU)continuously
monitorstheoperationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the
malfunctionindicatorlight(MIL)isilluminated.The
MIListheredlightlocatedintherightconsolepanel.

OncetheMILilluminates,initialtroubleshooting
checksshouldbemade.RefertotheMILsection
underTroubleshooting.

Ifthesechecksdonotcorrecttheproblem,further
diagnosisandservicingbyanAuthorizedService
Dealerisnecessary.

Replacingthe Low-PressureFuelFilter

ServiceInterval:Every200hours/Y early(whichever

comesrst)(moreoftenindirtyor
dustyconditions).

Thefuellterislocatedneartheengineonthefront
orrearsideoftheengine.

1.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedposition,andsetthe
parkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Allowthemachinetocooldown.

4.Closethefuel-shutoffvalveundertheseat
(Figure60).

45

Figure60

1.Fuellter

2.Hoseclamp

5.Squeezetheendsofthehoseclampstogether
andslidethemawayfromthelter(Figure60).

6.Removethelterfromthefuellines.

7.Installanewlterandmovethehoseclamps
closetothelter(Figure60).

8.Openthefuel-shutoffvalve.

Note:Itisimportanttoinstallthefuellinehosesand

securethemwithplastictiesthesameastheywere
originallyinstalledatthefactory,tokeepthefuelline
awayfromcomponentsthatcouldcausefuelline
damage.

3.Fuelline

ElectricalSystem
Maintenance

ServicingtheBattery

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

g008963

Batteryelectrolytecontainssulfuricacid
whichisadeadlypoisonandcausessevere
burns.

Donotdrinkelectrolyteandavoidcontact
withskin,eyesorclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.

RemovingtheBattery

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

DANGER

Servicingthe High-PressureFuelFilter

Donotattempttoservicethehigh-pressurefuellter.
Thehigh-pressurelterisintegratedwithinthefuel
pumpmodule.Thefuellterandothercomponents
insidethefuelpumpmodulearenotserviceable.Do
notattempttoopenthefuelpumpmodule.

EnsurethatanAuthorizedServiceDealerreplaces
thefuelpumpmodulewiththehigh-pressurefuellter.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan
AuthorizedServiceDealerdrainsthefueltank.

WARNING

Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponentscausing
sparks.Sparkscancausethebatterygases
toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

46

WARNING

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.
Sparkscancausethebatterygasesto
explode,resultinginpersonalinjury.

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

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

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Firstdisconnectthenegativebatterycable
(black)fromthenegative(-)(black)battery
terminal(Figure61).

4.Slidetheredterminalbootoffthepositive(red)
batteryterminalandremovethepositive(+)(red)
batterycable(Figure61).

5.Removethewingnutsecuringthebatteryclamp
(Figure61).

6.Removetheclamp(Figure61).

1.Removethewingnutand
clamp

2.Removethenegative
batterycablebeforethe
positive

g029644

g027728

Figure61

3.Removethepositive
batterycable

4.Removebattery

7.Removethebattery .

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminal
postsoppositefromthehydraulictank(Figure

61).

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

3.Theninstallthenegative(black)batterycable
andgroundwiretothenegative(-)battery
terminal.

4.Securethecableswith2bolts,2washers,and
2locknuts(Figure61).

5.Slidetheredterminalbootontothepositive
(red)batterypost.

6.Installtheclampandsecureitwiththewingnut
(Figure61).

47

ChargingtheBattery

ServicingtheFuses

WARNING

Chargingthebatteryproducesgasesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged

(1.265specicgravity).Thisisespecially
importanttopreventbatterydamagewhenthe
temperatureisbelow0°C(32°F).

1.Chargebatteryfor10to15minutesat25to30
ampsor30minutesat10amps.

2.Whenthebatteryisfullycharged,unplug
thechargerfromtheelectricaloutlet;then
disconnectthechargerleadsfromthebattery
posts(Figure62).

3.Installthebatteryinthemachineandconnect
thebatterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery

disconnected;electricaldamagemayoccur.

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

1.Thefusesarelocatedonrighthandconsole
nexttotheseat(Figure63).

2.Toreplacethefuses,pulloutonthefuseto
removeit.

3.Installanewfuse(Figure63).

1.Positivebatterypost

2.Negativebatterypost

Figure62

3.Red(+)chargerlead

4.Black(-)chargerlead

g020464

Figure63

1.Optional

accesory—15amp

2.Charge—25amp5.Console

3.PTO—10amp

4.Main—25amp

Jump-StartingtheMachine

1.Checkandcleancorrosionfromthebattery

g000960

terminalsbeforejump-starting.Ensurethatthe
connectionsaretight.

CAUTION

Corrosionorlooseconnectionscan
causeunwantedelectricalvoltagespikes
atanytimeduringthejump-starting
procedure.

Donotattempttojump-startwithloose
orcorrodedbatteryterminals,ordamage
totheengineorEFImayoccur.

48

DANGER

Jump-startingaweakbatterythatis
crackedorfrozen,orhasalowelectrolyte
leveloranopen/shortedbatterycellcan
causeanexplosionresultinginserious
personalinjury.

Donotjump-startaweakbatteryifthese
conditionsexist.

2.Makesurethattheboosterbatteryisagoodand
fullychargedlead-acidbatteryat12.6voltsor
greater.Useproperlysizedjumpercableswith
shortlengthstoreducevoltagedropbetween
systems.Makesurethatthecablesarecolor
codedorlabeledforthecorrectpolarity.

CAUTION

Connectingthejumpercablesincorrectly
(wrongpolarity)canimmediatelydamage
theEFIsystem.

Becertainofbatteryterminalpolarity
andjumpercablepolaritywhenhooking
upbatteries.

WARNING

Batteriescontainacidandproduce
explosivegases.

•Shieldtheeyesandfacefromthe
batteriesatalltimes.

Figure64

1.Positive(+)cableon
dischargedbattery

2.Positive(+)cableon
boosterbattery

3.Negative(–)cableonthe
boosterbattery

4.Negative(–)cableonthe
engineblock

5.Boosterbattery

6.Dischargedbattery

7.Engineblock

4.Connecttheotherendofthepositivecableto

thepositiveterminaloftheboosterbattery.

5.Connecttheblacknegative(–)cabletotheother

terminal(negative)oftheboosterbattery.

6.Makethenalconnectionontheengine

blockofthestalledvehicle(nottothe
negativebatterypost)awayfromthebattery
andstandback(Figure66).

g012785

•Donotleanoverthebatteries.

Note:Besuretheventcapsaretightandlevel.

Placeadampcloth,ifavailable,overanyvent
capsonbothbatteries.Besurethevehiclesdo
nottouchandthatbothelectricalsystemsareoff
andatthesameratedsystemvoltage.These
instructionsarefornegativegroundsystems
only.

3.Connectthepositive(+)cabletothepositive(+)
terminalofthedischargedbatterythatiswired
tothestarterorsolenoidasshowninFigure64.

1.Engineblock

g029644

Figure65

g013117

Figure66

2.Negative(–)cable

49

7.Startthevehicleandremovethecablesinthe
reverseorderofconnection(theengineblock
(black)connectionisthersttodisconnect).

DriveSystem
Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper
operationofretractorandbuckle.Replacebefore
operatingifdamaged.

CheckingtheKnobsonthe RolloverProtectionSystem (ROPS)

ServiceInterval:Beforeeachuseordaily

WARNING

Toavoidinjuryordeathfromrollover:keep
therollbarinthefullyraisedlockedposition
andusetheseatbelt.

Ensurethattherearpartoftheseatissecured
withtheseatlatch.

Checkthatboththemountinghardwareandtheknobs
areingoodworkingcondition.Makesuretheknobs
arefullyengagedwiththeROPSinthefullyraised
position.Theupperhoopoftherollbarmayneed
tobepushedforwardorpulledrearwardtogetboth
knobsfullyengaged.

50

8.Tightenthestopplate(Figure68).

Figure68

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

g029647

Figure67

1.ROPSknob(locked

position)

2.PullROPSknoboutand

rotate90degreesto
changerollbarposition

3.Rollbarintheupright
position

4.Rollbarinthefolded
position

AdjustingtheTracking

1.Disengagetheblade-controlswitch(PTO).

2.Drivetoanopenatarea,movethe
motion-controlleverstotheneutral-locked
position.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotion-controlleversalltheway
forwarduntiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust
theleftstopplaterearwardontheleftT-slotuntil
themachinetracksstraight(Figure68).

7.Ifittrackstotheleft,loosentheboltsandadjust
therightstopplaterearwardontherightT-slot
untilthemachinetracksstraight(Figure68).

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

g008943

Maintaintheairpressureinthereartiresat90kPa
(13psi).Uneventirepressurecancauseunevencut.
Checkthetireswhentheyarecold,togetthemost
accuratepressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddo

notrequireairpressuremaintenance.

comesrst)

g001055

Figure69

51

CheckingtheWheelLug Nuts

Checkandtorquethewheellugnutsto122to129
N-m(90to95ft-lb).

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

Checkandensurethatthetorqueoftheslottednutis
286to352N-m(211to260ft-lb).

Note:Donotuseanti-seizeonwheelhub.

Important:Makesurethatthespring

washersareinstalledcorrectlyasshownin

Figure71.

5.Installthedustcap(Figure71).

g001297

Figure71

Figure70

1.Slottednut

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Y early(whichever

comesrst)

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Removethedustcapfromthecasterandtighten
thelocknut(Figure71).

4.Tightenthelocknutuntilthespringwashersare
atandthenbackoffa1/4turntoproperlyset
thepre-loadonthebearings(Figure71).

1.Springwashers

2.Locknut

3.Dustcap

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwith
clutchesthatcontainabrakeshim.Whentheclutch

g029648

brakehasworntothepointwheretheclutchnolonger
engagesconsistently,theshimcanberemovedto
extendtheclutchlife.

g010869

Figure72

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

52

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartsto
stop,andremovethekey.Engagetheparking
brake.Allowthemachinetocoolcompletely
beforestartingtheseinstructions.

2.Usinganaircompressor,blowoutanydebris
fromunderthebrakepoleandaroundthebrake
spacers.

Figure73

3.Checktheconditionofthewireharnessleads,
connectors,andterminals.Cleanorrepairas
necessary.

4.Verifythat12Vispresentattheclutchconnector
whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandthe
armature.Ifthegapisgreaterthan1mm(0.04
inch),proceedwiththefollowingsteps:

A.Loosenbothbrakemountingboltsone-half

toonefullturnasshownbelow.

Note:Donotdiscardtheshimuntilproper

clutchfunctionhasbeenconrmed.

g010871

Figure75

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthe
brakespacers.

g010868

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

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

E.Usinga0.010inchthickfeelergauge,verify

thatagapispresentbetweentherotor
andarmaturefaceonbothsidesofthe
brakepoleasshown.(Duetothewaythe
rotorandarmaturefaceswear(peaksand
valleys)itissometimesdifculttomeasure
thetruegap.)

Note:Donotremovethebrakepolefrom

theeldshell/armature.Thebrakepolehas
worntomatchthearmatureandneedsto
continuetomatchaftertheshimisremoved
toensureproperbraketorque.

Figure74

1.Brakemountingbolt

B.Usingneedle-nosepliers,orbyhand,take

holdofthetabandremovetheshim.

g010872

Figure76

1.Feelergauge

g010870

g010873

Figure77

1.Feelergauge

53

•Ifthegapislessthan0.010inch,then

reinstalltheshimandreferencethe
Troubleshootingsection.

•Ifthegapissufcient,proceedtothe

safetycheckinstepF.

F.Performthefollowingsafetycheck:

CoolingSystem
Maintenance

CleaningtheEngineScreen

i.Sitontheseatandstarttheengine.

ii.Makesurethatthebladesdonot

engagewiththePTOswitchedoff
andtheclutchdisengaged.

Iftheclutchdoesnotdisengage,
installtheshimandreferencethe
Troubleshootingsection.

iii.EngageanddisengagethePTO

switch10consecutivetimesto
ensurethattheclutchisfunctioning
properly.Iftheclutchdoesnot
engageproperly ,referencethe

Troubleshootingsection.

andEngine-OilCooler

ServiceInterval:Beforeeachuseordaily

Removeanybuildupofgrass,dirt,orotherdebris
fromtheoilcooler(Figure78).

g029644

g009191

Figure78

Beforeeachuseremoveanybuildupofgrass,dirt,or
otherdebrisfromtheenginescreen.Thiswillhelp
ensureadequatecoolingandcorrectenginespeed
andwillreducethepossibilityofoverheatingand
mechanicaldamagetotheengine(Figure79).

CleaningtheEngine CoolingFinsandShrouds

ServiceInterval:Every100hours/Y early(whichever

comesrst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Removetheairintakescreen,recoilstarter,and
fanhousing(Figure79).

4.Cleanthedebrisandgrassfromtheengine
parts.

5.Installairintakescreen,recoilstarter,andfan
housing(Figure79).

54

g029645

Figure79

1.Engineguard4.Fanhousing

2.Engineairintakescreen

3.Bolt

5.Screw

CheckandCleanthe Hydraulic-UnitShrouds

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Raisetheseat.

4.Cleanthedebrisandgrassfromthehydraulic
unitshrouds(Figure80).

5.Lowertheseat.

g004218

Figure80

1.Hydraulicunitshrouds

g009920

55

BrakeMaintenance

AdjustingtheParking Brake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurethebrakeisadjustedproperly
beforeadjusting.

Note:Thisproceduremustbefollowedafterthe

rst100hoursorwhenabrakecomponenthasbeen
removedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandengagetheparkingbrake.

3.Stoptheengine,waitforallmovingpartsto
stop,andremovethekey .

4.Raisethebackofthemachineupandsupport
themachinewithjackstands.

DANGER

Mechanicalorhydraulicjacksmayfail
tosupportmachineandcauseaserious
injury.

•Usejackstandwhensupporting
machine.

•Donotusehydraulicjacks.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothe
releasedposition.RefertoUsingtheDrive

WheelReleaseV alves(page30).

8.Checktoseeifthereisavisiblegapbetween
theL-bracketandthelinkagestop(Figure81).

Figure81

LeftSideShown

1.L-bracket4.Rearlinkageassembly

2.Linkagestop

3.Gap

9.Disengagetheparkingbrake,thelevershould
beinthedownposition.

10.Turnthewheelhubbyhandinbothdirections
relativetothecaliper;thewheelhubshould
movefreelybetweenthecaliper.

11.Ifagapisneededorthewheelhubdoesnot
movefreely:

A.Disengagetheparkingbrake.

B.Disconnectandne-tunetherearlinkage

assembly:

5.Caliper

6.Wheelhub

•Shortenthelinktocreateagap.

•Lengthenthelinktoallowwheelhub

movement.

C.Reconnecttherearlinkageassembly .

12.Engagetheparkingbrakeandcheckthegap.

13.Repeatsteps9through13untilavisiblegapis
achievedandthewheelhubrotatesfreely.

14.Repeatthisprocedureforthebrakeonthe
oppositeside.

g026961

15.Rotatethedrivewheelreleasehandletothe
operatingposition.RefertoUsingtheDrive

WheelReleaseV alves(page30).

16.Installthereartiresandtorquethelugnuts.
RefertoCheckingtheWheelLugNuts(page

52).

17.Removethejackstands.

56

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating,
bladesslippingwhencuttinggrass,frayedbeltedges,
burnmarks,andcracks.Thesearesignsofaworn
mowerbelt;replacethemowerbeltifanyofthese
conditionsareevident.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslipping
whencuttinggrass,frayedbeltedges,burnmarks,
andcracksaresignsofawornmowerbelt.Replace
themowerbeltifanyoftheseconditionsareevident.

1.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedposition,andsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Lowerthemowertothe76mm(3inch)height
ofcut.

4.Removethebeltcovers(Figure82).

Figure82

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarm
toremovetensionontheidlerspring(Figure83).

6.Removethebeltfromthemowerdeckpulleys.

g009038

Figure83

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt

3.Spring-loadedidlerpulley

4.Ratchet

armfortheratchet

6.Idlergreasetting

7.Beltguide

10.Installthebeltguideontheidlerarmshownin

Figure83.

11.Usingtheratchetinthesquarehole,installthe
idlerspring(Figure83).

Makesurethatthespringendsareseatedin

g027729

theanchorgrooves.

12.Installthebeltcovers(Figure84).

7.Removethebeltguideonthespring-loaded
idlerarmshowninFigure83.

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleys
andtheclutchpulleyundertheengine(Figure

83).

57

Figure84

1.Positionthebeltcover3.Ensurethatthetabis

underthemetalcatch

2.Slidebeltcoverunderthe

sidecatches

ReplacingtheHydraulic

g027730

g009039

Figure85

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Right-handhydraulic
pumppulley

5.Left-handhydraulicpump
pulley

PumpDriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Removethemowerbelt.RefertoReplacingthe
MowerBeltinMaintenance.

4.Raisethemachineandsupportitwithjack
stands(Figure85).

5.Usearatchetinthesquareholeintheidlerarm
toremovetheidlerspring(Figure85).

6.Unhooktheidlerspringfromtheframe(Figure

85).

7.Removethebeltfromthehydraulicunitdrive
pulleysandtheenginepulley

8.Installthenewbeltaroundenginepulleyand
thetwodrivepulleys.

9.Usingaratchetinthesquareholeintheidler
arm,installtheidlerspringtotheframe(Figure

85).

10.Installthemowerbelt.RefertoReplacingthe
MowerBelt.

58

ControlsSystem
Maintenance

AdjustingtheControl HandlePosition

Thereare2heightpositionsforthecontrollevers:
highandlow.Removetheboltstoadjusttheheight
fortheoperator.

1.DisengagethePTO,movethemotion-control
leverstotheneutral-lockedposition,andsetthe
parkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Loosentheboltsandangenutsinstalledinthe
levers(Figure86).

4.Alignthefront-to-rearpositionofthelevers
bybringingtheleverstogethertotheneutral
positionandslidingthemuntiltheyarealigned;
thentightenthebolts(Figure87).

g009195

Figure87

Adjustingthe Motion-ControlLinkage

Figure86

1.Bolt

2.Handle4.Nut

3.Controllever

Locatedoneithersideofthefueltank,belowtheseat
arethepumpcontrollinkages.Rotatingthepump
linkagewitha1/2inchwrenchallowsnetuning
adjustmentssothatthemachinedoesnotmovein
neutral.Anyadjustmentsshouldbemadeforneutral
positioningonly.

WARNING

Theenginemustberunningandthedrive
wheelsmustbeturningsothatthemotion

g029726

controladjustmentcanbeperformed.Contact
withmovingpartsorhotsurfacesmaycause
personalinjury.

Keepngers,hands,andclothingclearof
rotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift
pedal,removetheheight-of-cutpin,andlower
thedecktotheground.

2.Raisetherearofthemachineupandsupportit
withjackstands(orequivalentsupport)justhigh
enoughtoallowthedrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat
safetyswitch,locatedunderthebottomcushion
oftheseat.

Note:Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrossthe
terminalsintheconnectorofthemainwiring
harness.

59

5.Starttheengine.

12.Raisethedeckandinstalltheheight-of-cutpin.

Note:Thebrakemustbeengaged,andthe

motion-controlleversout,tostarttheengine.
Theoperatordoesnothavetobeintheseat
becauseofthejumperwirebeingused.Run

theengineatfullthrottleandreleasethebrake.

6.Runthemachineatleast5minuteswiththe
driveleversatfullforwardspeedtobring
hydraulicoiluptooperatingtemperature.

Note:Themotion-controlleverneedsto

beinneutralwhilemakinganynecessary
adjustments.

7.Bringthemotion-controlleversintotheneutral
position.

8.Adjustthepumpcontrolrodlengthsbyrotating
thedoublenutsontherodintheappropriate
directionuntilthewheelsslightlycreepin
reverse(Figure88).

13.Checkthatthemachinedoesnotcreepin
neutralwiththeparkingbrakedisengaged.

Adjustingthe Motion-ControlDamper

Thetopdampermountingboltcanbeadjustedto
obtainamoredesiredmotion-controlleverresistance.
SeeFigure89formountingoptions.

Figure88

1.Doublenuts

9.Movethemotion-controlleverstothereverse
positionandwhileapplyingslightpressureto
theleverallowthereverseindicatorspringsto
bringtheleversbacktoneutral.

Note:Thewheelsmuststopturningorslightly

creepinreverse.

10.Stoptheengine,removethejumperwirefrom
thewireharness,andplugtheconnectorinto
theseatswitch.

11.Removethejackstands.

g008620

Figure89

Right-handmotioncontrolshown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

Adjustingthe
Motion-ControlNeutral

g029649

LockPivot

Theangednutcanbeadjustedtoobtainamore
desiredmotion-controlleverresistancewhenmoving
ittotheneutrallockposition.SeeFigure90for
adjustmentoptions.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesired

feel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenthejamnut.

60

HydraulicSystem
Maintenance

ServicingtheHydraulic System

Figure90

1.Flangednut2.Jamnut

g008621

HydraulicOilType:T oro
oilorMobil

®

115W-50.

®

HYPR-OIL

™

500hydraulic

Important:Useoilspecied.Otheruidscould

causesystemdamage.

EachHydraulicSystemOilCapacity:1.5L(1.59

USqt)persidewithlterchange

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthe

hydraulicoillevel.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotion-control

leverstotheneutral-lockedpositionandsetthe
parkingbrake.

3.Stoptheengine,removethekey,andwait

forallmovingpartstostopbeforeleavingthe
operatingposition.

4.Allowtheengineandthehydraulicsystemto

coolfor10minutes.

Note:Theoillevelonthedipstickwillbe

incorrectiftheoilischeckedwhenthemachine
ishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofthe

hydraulic-systemreservoirs(Figure91).

7.Removeonedipstickfromthehydraulicreservoir

(Figure91).

8.Wipethedipstickoffandthreadthedipstickinto

thereservoir.

9.Removethedipstickandlookattheend(Figure

91).Iftheoillevelisattheaddmark,slowly

pouronlyenoughoilintothehydraulicreservoir
toraisetheleveltothefullorHline.

Important:Donotoverllthehydraulic

unitswithoilasdamagemayoccur.Donot
runthemachinewiththeoilbelowtheadd
mark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

61

ReplacingtheHydraulicFilters andHydraulicOil

ServiceInterval:Aftertherst250hours—Change

thehydraulicltersandhydraulicoil
whenusinganytypeofoil.

Figure91

Eitherdipstickwillbeusedinthemachine

1.Full3.H—meanshighlevel

2.Add4.Dipsticklocationsunder
seat

Every250hours—Changethehydrauliclters
andhydraulicoilwhenusingMobil

®

1oil(more

oftenindirtyordustyconditions).

Every500hours—Changethehydrauliclters
andhydraulicoilwhenusingT oro

®

HYPR-OIL

™

500hydraulicoil(moreoftenindirtyordusty
conditions).

Toreplacethehydraulicoil,theltersneedtobe
removed.Replacebothatthesametime.Referto
theoilspecicationsunderServicingtheHydraulic

System(page61)forthecorrectoil.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe

g015459

operatingposition.

3.Raisethemachineandsupportitwithjack
stands(Figure92).

WARNING

Hydraulicoilescapingunderpressure
canpenetrateskinandcauseinjury .

•Ifhydraulicoilisinjectedintotheskin
itmustbesurgicallyremovedwithin
afewhoursbyadoctorfamiliarwith
thistypeofinjury.Gangrenemay
resultifthisisnotdone.

•Keepbodyandhandsawayfrompin
holeleaksornozzlesthatejecthigh
pressurehydraulicoil.

•Usecardboardorpapertond
hydraulicleaks.

•Safelyrelieveallpressureinthe
hydraulicsystembeforeperforming
anyworkonthehydraulicsystem.

•Makesureallhydraulicoilhosesand
linesareingoodconditionandall
hydraulicconnectionsandttings
aretightbeforeapplyingpressureto
hydraulicsystem.

g008970

Figure92

1.Jackstands

4.Removeboththemowerbeltandthepump
drivebelt.Thiswillpreventoilgettingonthe
belts.RefertoBeltMaintenance(page57).

5.Placeadrainpanunderthelter,removethe
oldlterandwipethesurfaceclean(Figure93).

62

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethatthemowerdeckisleveledbefore

matchingtheheightofcut(HOC).

1.Positionthemachineonaatsurface.

2.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

3.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

g008968

Figure93

BottomViewofMachine

1.Filterlocations

2.Hydrauliclter

4.Checkthetirepressureofthedrivetires.If
needed,adjustthepressureto90kPa(13psi)

5.Positionthemowertothe76mm(3inch)
height-of-cutposition.

6.Applyathincoatofhydraulicoiltotherubber
gasketonthereplacementlter(Figure93).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine
(Figure92).

10.Addoiltothehydraulicreservoirandcheckfor
anyleaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwo
minutestopurgeairfromthesystem.Stopthe
engineandcheckforleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Do
notoverll.

LevelingtheDeck

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,
andremovekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper
inationpressurefortiresis90kPa(13psi).
Adjustifnecessary.

4.Positionthetransportlockinthelatching
position.

5.Pushthedeckliftpedalallthewayforwardand
thedeckwilllatchatthe14cm(5-1/2inch)
transportposition(Figure94).

1.Deck-liftpedal

2.Height-of-cutpin

63

g029840

Figure94

3.Transportlock

6.Inserttheheight-adjustmentpinintothe7.6cm
(3inch)cutting-heightposition.

7.Releasethetransportlockandallowthedeckto
lowertothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthe
levelsurfacetothefronttipoftheblade(Postion
A).Themeasurementshouldread7.6mm(3
inches);refertoFigure95.

Figure95

1.7.6cm(3inches)atAis

correct

2.8.3cm(3-1/4inches)atB

iscorrect

3.Measureherefromthe
bladetiptohardsurface

4.MeasureatAandBon
bothsides

g029650

Figure96

1.Flangedlocknut3.Jamnut

2.Adjusterscrew4.Y oke

11.Ifthefrontdecklinksdonothaveenough
adjustmenttoachieveaccuratecutheight,the
singlepointadjustmentcanbeutilizedtogain
moreadjustment.

g009196

12.T oadjustthesinglepointsystem,loosenthetwo
boltsatthebottomoftheheight-of-cutplate.
RefertoFigure97.

10.Ifneeded,loosentheangedlocknutontheside
oftheyokeandthejamnutontop.Fine-tune
theadjusterscrewbyturningittoget7.6mm(3
inch)height(Figure96).

Toincreasetheheight,turntheadjusterscrew
clockwise;todecreasetheheight,turnit
counterclockwise.

g029651

Figure97

1.Boltsatthebottomoftheheight-of-cutplate

13.Ifthedeckistoolow,tightenthesinglepoint
adjustmentboltbyrotatingitclockwise.If
thedeckistoohigh,loosenthesinglepoint
adjustmentboltbyrotatingitcounterclockwise
(Figure98).

Note:Loosenortightenthesinglepoint

adjustmentboltenoughtomovethe
height-of-cutplatemountingboltsatleast1/3
thelengthoftheavailabletravelintheirslots.

64

Thiswillregainsomeup-and-downadjustment
oneachofthe4decklinks.

sharpeningandreplacement,youmaywanttokeep
extrabladesonhand.

DANGER

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

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe

Figure98

1.Singlepointadjustmentbolt

14.Tightenthe2boltsatthebottomofthe
height-of-cutplate(Figure97).T orquethemto
37to45N-m(27to33ft-lb).

Note:Inmostconditions,thebackbladetip

shouldbeadjusted6.4mm(1/4inch)higher
thanthefront.

15.Onbothsidesofthedeck,measurefromthe
levelsurfacetothebacktipoftheblade(Postion
B).Themeasurementshouldread8.3cm(3-1/4
inches);refertoFigure95.

16.Fine-tunetheadjusterscrewbyturningittoget

8.3mm(3-1/4inches)height(Figure96).

Toincreasetheheight,turntheadjustmentnut
clockwise;todecreasetheheight,turnthenut
counterclockwise.

17.Measureuntilall4sidesarethecorrectheight.
Tightenallthejamnutsonthedeck-liftarm
assemblies.

18.Lowerthedischargechute.

g017036

Blades

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

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure99).Ifthe
edgesarenotsharporhavenicks,removeand
sharpentheblades.RefertoSharpeningthe
Blades.

2.Inspecttheblades,especiallythecurvedarea
(Figure99).Ifyounoticeanydamage,wear,ora
slotforminginthisarea(Figure99),immediately
installanewblade.

ServicingtheCutting Blades

Maintainsharpbladesthroughoutthecuttingseason,
becausesharpbladescutcleanlywithouttearingor
shreddingthegrassblades.T earingandshredding
turnsgrassbrownattheedges,whichslowsgrowth
andincreasesthechanceofdisease.

Checkthecutterbladesdailyforsharpness,and
foranywearordamage.Filedownanynicksand
sharpenthebladesasnecessary.Ifabladeis
damagedorworn,replaceitimmediatelywitha
genuineTororeplacementblade.Forconvenient

g006530

Figure99

1.Cuttingedge3.Wear/slotforming

2.Curvedarea4.Crack

CheckingforBentBlades

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

65

3.Rotatethebladesuntiltheendsfaceforward
andbackward(Figure100).Measurefroma
levelsurfacetothecuttingedge,positionA,of
theblades(Figure100).Notethisdimension.

g004536

Figure101

Figure100

1.Measureherefromblade

tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedge
ofthebladesatthesamepositionasinstep3
above.Thedifferencebetweenthedimensions
obtainedinsteps3and4mustnotexceed
1/8inch(3mm).Ifthisdimensionexceeds
1/8inch(3mm),thebladeisbentandmust
bereplaced;refertoRemovingtheBladesand
InstallingtheBlades.

WARNING

Abladethatisbentordamagedcould
breakapartandcouldseriouslyinjureor
killyouorbystanders.

•Alwaysreplacebentordamaged
bladewithanewblade.

•Neverleorcreatesharpnotchesin
theedgesorsurfacesofblade.

g000975

1.Sailareaofblade3.Curvedwasher

2.Blade4.Bladebolt

SharpeningtheBlades

WARNING

Whensharpeningblades,piecesofablade
couldbethrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpening
blades.

1.Usealetosharpenthecuttingedgeatboth
endsoftheblade(Figure102).Maintainthe
originalangle.Thebladeretainsitsbalanceif
thesameamountofmaterialisremovedfrom
bothcuttingedges.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe
bladeisoutofbalanceorisbent.T oensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineTororeplacementblades.
Replacementbladesmadebyothermanufacturers
mayresultinnon-conformancewithsafetystandards.

1.Holdthebladeendusingaragorthickly-padded
glove.

2.Removethebladebolt,curvedwasher,and
bladefromthespindleshaft(Figure101).

g000276

Figure102

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure103).Ifthebladestays
inahorizontalposition,thebladeisbalanced
andcanbeused.Ifthebladeisnotbalanced,
lesomemetalofftheendofthesailareaonly
(Figure104).Repeatthisprocedureuntilthe
bladeisbalanced.

66

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure

104).

Figure103

1.Blade2.Balancer

g000277

Important:Thecurvedpartoftheblade

mustbepointingupwardtowardtheinside
ofthemowertoensurepropercutting.

2.Installthespringdiskandthebladebolt.The
springdiskconemustbeinstalledtowardthe
bolthead(Figure104).T orquethebladeboltto
115to150N-m(85to110ft-lb).

67

1.Sailareaofblade

2.Blade

3.Curvedwasher

Figure104

4.Bladebolt

5.Conetowardsbolthead

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,the
spring-loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy.
Removingthedeckwithoutreleasingthe
storedenergycancauseseriousinjuryor
death.

Donotattempttodisassemblethedeckfrom
thefrontframewithoutlockingoutthestored
energy.

1.Stoptheengine,waitforallmovingpartstostop,

g004536

andremovethekey.Engagetheparkingbrake.

2.Removetheheight-adjustmentpinandlower
thedecktotheground.

3.Placetheheight-adjustmentpininthe7.6cm(3
inch)cutting-heightlocation.

Note:Thislocksthedeckliftarmsinthelowest

positionwhenthedeckisremovedandthe
storedenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothe
squareholeinthedeckidler(Figure105).

6.Rotatethedeckidlerclockwiseandremovethe
mowerbelt(Figure105).

68

Figure105

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt

3.Spring-loadedidlerpulley

4.Ratchet

armfortheratchet

6.Idlergreasetting

7.Beltguide

7.Removeandretainthehardwareonbothsides
ofthedeckasshowninFigure106.

g029652

Figure106

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

g009038

8.Raisethedeckstrutsandsecurethemintheup
position.Slidethedeckouttotherightsideof
themachine.

ReplacingtheGrass
Deector

WARNING

Operatingthemachinewiththeengine
runningataspeedgreaterthanthefactory
settingcancausethemachinetothrowapart
ofthebladeorenginetowardtheoperatoror
abystanderandresultinseriouspersonal
injuryordeath.

Neveroperatethemachineunlessyouinstall
acoverplate,amulchplate,agrassdeector,
orabagger.

1.Removethelocknut,bolt,spring,andspacer
holdingthedeectortothepivotbrackets
(Figure107).Removethedamagedorworn
grassdeector.

69

Figure107

Cleaning

CleaningundertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheneutral-locked
positionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

g015594

3.Raisethemowertothetransportposition.

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

2.Placethespacerandthespringontothegrass

deector.PlaceoneJendofthespringbehind
thedeckedge.

5.Springinstalled

7.J-hookendofspring

Note:MakesureoneJ-endofthespringis

installedbehindthedeckedgebeforeinstalling
theboltasshowninFigure107.

3.Installtheboltandthenut.PlaceoneJ-hook

endofthespringaroundthegrassdeector
(Figure107).

Important:Thegrassdeectormustbeable

torotate.Liftthedeectoruptothefullopen
positionandensurethatitrotatesintothe
fulldownposition.

CleaningtheSuspension System

Note:Donotcleantheshockassemblieswith

pressurizedwater.

g030538

Figure108

DisposingofWaste

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

70

Storage

CleaningandStorage

1.Disengagethepowertakeoff(blade-control
switch(PTO),settheparkingbrake,andturn
theignitionkeytoOff.Removethekey.

2.Removegrassclippings,dirt,andgrimefromthe
externalpartsoftheentiremachine,especially
theengineandhydraulicsystem.Cleandirtand
chafffromtheoutsideoftheenginecylinder
headnsandblowerhousing.

Important:Youcanwashthemachinewith

milddetergentandwater.Donotpressure
washthemachine.Avoidexcessiveuse
ofwater,especiallynearthecontrolpanel,
engine,hydraulicpumps,andmotors.

3.Checkthebrake;refertoBrakeMaintenance

(page56).

4.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page39).

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrain

thefueltank;refertoServicingtheFuel

Tank(page46).

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasper

localcodes.

Important:Donotstore

stabilizer/conditionedfuelover
90days.

13.Checkandtightenallbolts,nuts,andscrews.
Repairorreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paint
isavailablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageor
storagearea.Removethekeyfromtheignition
switchandkeepitoutofreachofchildrenor
otherunauthorizedusers.Coverthemachineto
protectitandkeepitclean.

5.Greasethemachine;refertoLubrication(page

36)

6.Changethecrankcaseoil;refertoChangingthe

EngineOil(page41).

7.Checkthetirepressure;refertoCheckingthe

TirePressure(page51).

8.Changethehydrauliclters;refertoServicing

theHydraulicSystem(page61).

9.Chargethebattery;refertoChargingtheBattery

(page48).

10.Scrapeanyheavybuildupofgrassanddirt
fromtheundersideofthemower,thenwashthe
mowerwithagardenhose.

Note:Runthemachinewiththeblade-control

switch(PTO)engagedandtheengineathigh
idlefor2to5minutesafterwashing.

11.Checktheconditionoftheblades;referto

ServicingtheCuttingBlades(page65).

12.Forstorageover30days,preparethemachine
asfollows:

A.Addapetroleum-based

stabilizer/conditionertofuelinthe
tank.Followthemixinginstructionsfrom
thestabilizermanufacturer.Donotuse
analcohol-basedstabilizer(ethanolor
methanol).

Note:Afuelstabilizer/conditionerismost

effectivewhenmixedwithfreshfueland
usedatalltimes.

71

Troubleshooting

Problem

ThemalfunctionIndicatorLight(MIL)
comeson.

Thestarterdoesnotcrank.

PossibleCauseCorrectiveAction

1.Theengineistoohot.

2.Thereisoldgasinthegastank.2.Usenewgas.

3.Thefuelshut-offvalveisnotopen
completely.

4.Theaircleanerisdirty.4.Makesurethattheaircleanerand

5.Thebatteryisnotcharged.

6.Incorrectfuelltersarebeingusedor
thefuelltersaredirty.

7.Theconnectionstothesensors
electroniccontrolunit(ECU)andfuel
injectorsarenotsecuredproperly .

8.Thereislowvoltagefromthebattery.

9.Afuseisblown.9.Checkandreplaceanyblownfuses.

1.Theblade-controlswitch(PTO)is
engaged.

2.Theparkingbrakeisnoton.

3.Themotion-controlleversarenotin
theneutral-lockposition.

4.Theoperatorisnotseated.

5.Thebatteryisdead.

6.Theelectricalconnectionsare
corrodedorloose.

7.Thefuseisblown.7.Replacethefuse.

8.Therelayorswitchiswornor
damaged.

1.Turntheengineoffandletitcool.

3.Openthefuelshut-offvalve.

precleanerareclean.Replaceif
necessary.

5.Chargeorreplacethebattery.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

8.Ensureagood12voltbatteryisbeing
usedandisfullycharged.

1.Movetheblade-controlswitch(PTO)
tothedisengagedposition.

2.Settheparkingbrake.

3.Ensurethatthemotion-controllevers
areintheneutral-lockposition.

4.Sitontheseat.

5.Chargethebattery.

6.Checktheelectricalconnectionsfor
goodcontact.

8.ContactanAuthorizedServiceDealer.

Theenginedoesnotstart,startshard,or
failstokeeprunning.

1.Thefueltankisempty.1.Fillthefueltank.

2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thethrottleisnotinthecorrect
position.

5.Thereisdirtinthefuellter.5.Replacethefuellter.

6.Thereisdirt,water,orstalefuelisin
thefuelsystem.

7.Theaircleanerisdirty.

8.Theseatswitchisnotfunctioning
properly.

9.Theelectricalconnectionsare
corroded,loose,ordamaged.

10.Therelayorswitchiswornor
damaged.

11.Thesparkplugisfouledorimproperly
gapped.

12.Thespark-plugwireisnotconnected.

4.Besurethatthethrottlecontrolis
midwaybetweentheslowandfast
positions.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheair-cleaner
element.

8.Checktheseat-switchindicator.
Replacetheseatifnecessary .

9.Checktheelectricalconnections
forgoodcontact.Cleanthe
connectorterminalsthoroughlywith
electrical-contactcleaner,apply
dielectricgrease,andmakethe
appropriateconnections.

10.ContactanAuthorizedServiceDealer.

11.Adjustorreplacethesparkplug.

12.Checkthespark-plugwireconnection.

72

Problem

PossibleCauseCorrectiveAction

Theenginelosespower.

Theengineoverheats.

Themowerpullstotheleftorright(with
leversfullyforward)

Themachinedoesnotdrive.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandtheairpassages
abovetheengineareplugged.

5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

7.Thereisdirt,water,orstalefuelisin
thefuelsystem.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandtheairpassages
abovetheengineareplugged.

1.Thetrackingneedsadjustment1.Adjustthetracking.

2.Thetirepressureinthedrivetiresis
notcorrect.

1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.

2.Thepumpbeltisworn,loose,or
broken.

3.Thepumpbeltisoffapulley.3.Changethebelt.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

5.Thehydraulicoillevelislowortoohot.5.Addhydraulicoiltothereservoirsor

2.Cleantheair-cleanerelement.

4.Removetheobstructionfromthe
coolingnsandtheairpassages.

7.ContactanAuthorizedServiceDealer.

3.Removetheobstructionfromthe
coolingnsandtheairpassages.

2.Adjustthetirepressureinthedrive
tires.

2.Changethebelt.

letitcooldown.

Themachinevibratesabnormally .

Themachineproducesanunevencutting
height.

Thebladesdonotrotate.

1.Thecuttingblade(s)is/arebentor
unbalanced.

2.Theblademountingboltisloose.2.Tightentheblademountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Theenginepulley ,idlerpulley,orblade
pulleyisloose.

5.Theenginepulleyisdamaged.

6.Thebladespindleisbent.

7.Themotormountislooseorworn.

1.Theblade(s)is/arenotsharp.1.Sharpentheblade(s).

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

3.Themowerdeckisnotlevel.

4.Theundersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.

6.Thebladespindleisbent.

1.Themowerdeckbeltisworn,loose,
orbroken.

2.Themowerdeckbeltisoffpulley.

Thepumpdrivebeltisworn,loose,or

3.
broken.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

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

6.ContactanAuthorizedServiceDealer.

1.Installanewdeckbelt.

2.Installthemowerdeckpulleyand
checktheidlerpulley,idlerarm,and
springforcorrectpositionandfunction.

3.Checkthebelttensionorinstallanew
belt.

73

Problem

PossibleCauseCorrectiveAction

Theclutchdoesnotengage.

1.Thefuseisblown.1.Replacethefuse.Checkthecoil

2.Thereislowvoltagesupplyatthe
clutch.

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead

5.Therotor/armatureairgapistoolarge.

resistance,batterycharge,charging
system,andwiringconnections,and
replacecomponentsifnecessary.

2.Checkthecoilresistance,battery
charge,chargingsystem,andwiring
connectionsandreplacepartsif
necessary.

wireorelectricalsystem.Cleanthe
connectorcontacts.

5.Removetheshimorreplacetheclutch.

74

Schematics

BN

BN

BU

BK

Y

W

T

PK

BN

PK

OR

GN

S R

PK PK

PK

LTGR

GY

GY

PK

V

BN

V

OR

GN

OR

R

PK R BK

T

R

BK

GND

PK

BK

BN

BN

BK PK

BK

GND

15A

F4

GY

R

IBA

W

V

BU

V

V

BK

+

S

-

FUEL SENDER

10A

F3

(BRAKE)

SW6

PK

OR

R

F2

25A

PTO

CLUTCH

BU

1

2

5

4

7

8

(PTO SWITCH)

SW2

25A

LAMP

F1

(SEAT)

SW7

2

3

5

4

1

K2

(START RELAY)

TVS DIODE

U2

(NEUT_R)

SW5

B+

MAG

ECU

REG

START

AC

STARTER

+-

AC

IGNITION

MODULES

SPARK PLUGSPARK PLUG

KOHLER EFI

(NEUT_L)

SW4

12

B+

10

KEY_S

9

KEY_A

4

SEAT

11

BRAKE

2

NEUTRAL

3

PTO

5

FUEL

1

START_RELAY

7

MAGNETO

6

FUEL_SOLENOID

8

GROUND

HOUR METER

2

R A

I

A

4

7

1 3

6

5

A

3

SW1

1

B

B

C

B

8

2

4

5

(IGNITION)

6

5

1

KEY SW

OPTIONAL

ACCESSORIES

2

S

Ignition switch terminal locations

viewed from back

OFF = no connections

ON = BRIA

START = BRIS

BK = BLACK

BN = BROWN

BU = BLUE

GN = GREEN

GY = GREY

LT GR = LIGHT GREEN

OR = ORANGE

PK = PINK

R = RED

T = T

AN

V = VIOLET

W = WHITE

WireDiagram(Rev .A)

75

g013119

TheToroTotalCoverageWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment
(LCE)

ConditionsandProductsCovered

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

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

4

•Engines

Mid-SizeWalk-BehindMowers

4

•Engines

GrandStand

4

•Engines

•Frame

®

ZMaster

•Engines

2000SeriesMowers

4

•Frame

®

ZMaster

•Engines

•Frame

ZMaster

•Engines

4

®

4

3000SeriesMowers

5000SeriesMowers

®

Mowers

Kawasaki–3years

2years

Kawasaki–3years

5yearsor1,200hours

3years

Lifetime(originalowneronly)

4yearsor500hours

3years

Lifetime(originalowneronly)

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

KohlerCommand–2years

KohlerEFI–3years

•Frame

®

ZMaster

•Engines

6000SeriesMowers

4

•Frame

®

ZMaster

•Engines

7000SeriesMowers

4

•Frame

Lifetime(originalowneronly)

5yearsor1,200hours

Kawasaki–3years

Lifetime(originalowneronly)

5yearsor1,200hours

2years

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

1

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

2

Whicheveroccursrst.

3

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atT oro'soption,underwarrantyatnocostforpartsand
labor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosion
arenotcovered.

4

SomeenginesusedonT oroProductsarewarrantedbytheenginemanufacturer.

1

1

2

3

2

3

2

3

2

3

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InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship,
followthisprocedure:

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

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

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith
theassistanceprovided,contactusat:

RLCCustomerCareDepartment

ToroWarrantyCompany

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

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

888-865-5691(Canadacustomers)

OwnerResponsibilities

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

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage
andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot
coverthefollowing:

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

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

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenalteredormisusedorneglectedandrequires

replacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedToroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult

Operator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan

10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro
ServiceDealerusingToroapprovedreplacementparts.

NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect,
incidentalorconsequentialdamagesinconnectionwiththeuseoftheToro
Productscoveredbythiswarranty ,includinganycostorexpenseofproviding
substituteequipmentorserviceduringreasonableperiodsofmalfunctionor
non-usependingcompletionofrepairsunderthiswarranty .

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

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages,
orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions
andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

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

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.

374-0252RevF