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74991 Z Master Professional 5000 Series
Operator's Manual
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Toro 74991 Z Master Professional 5000 Series Operator's Manual

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Page 1
FormNo.3400-705RevB
g029833
ZMaster
®
Professional5000
SeriesRidingMower
with60inTURBOFORCE Mower
ModelNo.74991—SerialNo.316000001andUp
®
SideDischarge
Registeratwww.T oro.com. OriginalInstructions(EN)
*3400-705*B
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemicalorchemicals
knowntotheStateofCaliforniatocausecancer,
birthdefects,orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadianICES-002
ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineonany forest-covered,brush-covered,orgrass-coveredlandunless theengineisequippedwithasparkarrester,asdenedin Section4442,maintainedineffectiveworkingorderorthe engineisconstructed,equipped,andmaintainedforthe preventionofre.
YoumaycontactTorodirectlyatwww .Toro.comforproduct safetyandoperationtrainingmaterials,accessoryinformation, helpndingadealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineT oroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready.Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.
WARNING
Removingstandardoriginalequipmentpartsand accessoriesmayalterthewarranty,traction,and safetyofthemachine.FailuretouseoriginalToro partscouldcauseseriousinjuryordeath.Making unauthorizedchangestotheengine,fuelorventing system,mayviolateEPAandCARBregulations.
Replaceallpartsincluding,butnotlimitedto,tires, belts,blades,andfuelsystemcomponentswith originalToroparts.
Theenclosed informationregardingtheUSEnvironmentalProtection Agency(EPA)andtheCaliforniaEmissionControl Regulationofemissionsystems,maintenance,and warranty.Replacementsmaybeorderedthroughthe enginemanufacturer.
Engine Owner's Man ual
issuppliedfor
Introduction
Thisrotary-blade,ridinglawnmowerisintendedtobeused byresidentialhomeownersorprofessional,hiredoperators. Itisdesignedprimarilyforcuttinggrassonwell-maintained lawnsonresidentialorcommercialproperties.Itisnot designedforcuttingbrushorforagriculturaluses.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafety-alertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.
Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely.
©2016—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA
AllRightsReserved
Page 3
Contents
Safety...........................................................................4
SafeOperatingPractices...........................................4
ToroMowerSafety..................................................6
SlopeIndicator.......................................................7
SafetyandInstructionalDecals.................................8
ProductOverview.........................................................14
Controls...............................................................14
Specications........................................................15
Operation....................................................................16
AddingFuel...........................................................16
CheckingtheEngine-OilLevel.................................17
BreakinginaNewMachine......................................17
UsingtheRollover-ProtectionSystem(ROPS)............17
EnteringtheOperatingPosition...............................18
ThinkSafetyFirst...................................................18
OperatingtheParkingBrake....................................19
OperatingtheMowerBlade-ControlSwitch
(PTO)...............................................................20
OperatingtheThrottle............................................20
OperatingtheIgnitionSwitch..................................20
UsingtheFuel-ShutoffValve...................................20
StartingandShuttingOfftheEngine.........................21
UsingtheSafety-InterlockSystem.............................22
DrivingForwardorBackward..................................23
ShuttingOfftheMachine........................................24
AdjustingtheHeightofCut.....................................24
AdjustingtheAnti-ScalpRollers...............................25
AdjustingtheFlow-Bafe-CamLocks.......................26
PositioningtheFlowBafe......................................26
PositioningtheSeat................................................27
UnlatchingtheSeat.................................................27
AdjustingtheMyRide™SuspensionSystem...............28
UsingtheDrive-WheelReleaseValves.......................29
UsingtheSideDischarge.........................................29
TransportingtheMachine........................................30
LoadingtheMachine..............................................30
OperatingTips......................................................32
Maintenance.................................................................33
RecommendedMaintenanceSchedule(s)......................33
Lubrication...............................................................34
AddingLightOilorSprayLubrication.......................34
GreasingtheMower...............................................35
LubricatingtheCaster-WheelHubs...........................36
EngineMaintenance..................................................37
ServicingtheAirCleaner.........................................37
ServicingtheEngineOil..........................................38
ServicingtheSparkPlug..........................................40
CheckingtheSparkArrester(ifEquipped).................42
FuelSystemMaintenance...........................................42
ServicingtheElectronicFuel-Injection
System..............................................................42
ReplacingtheLow-PressureFuelFilter......................42
ServicingtheHigh-PressureFuelFilter......................43
ServicingtheFuelTank...........................................43
ElectricalSystemMaintenance....................................43
ServicingtheBattery...............................................43
ServicingtheFuses.................................................45
Jump-StartingtheMachine......................................45
DriveSystemMaintenance.........................................46
CheckingtheSeatBelt.............................................46
CheckingtheRollover-Protection-System(ROPS)
Knobs...............................................................46
AdjustingtheTracking............................................47
CheckingtheTirePressure......................................48
CheckingtheWheelLugNuts..................................48
CheckingtheWheelHubSlottedNut........................48
AdjustingtheCaster-PivotBearing............................49
UsingtheClutchShim............................................49
CoolingSystemMaintenance......................................51
CleaningtheEngineScreenandEngine-Oil
Cooler...............................................................51
CleaningtheEngineCoolingFinsand
Shrouds.............................................................52
CleaningtheHydraulicUnits....................................52
BrakeMaintenance....................................................53
AdjustingtheParkingBrake.....................................53
BeltMaintenance......................................................54
InspectingtheBelts................................................54
ReplacingtheMowerBelt........................................54
ReplacingtheHydraulic-PumpDriveBelt..................55
ControlsSystemMaintenance.....................................56
AdjustingtheControl-HandlePosition......................56
AdjustingtheMotion-ControlLinkage......................56
AdjustingtheMotion-ControlDamper.....................57
AdjustingtheMotion-ControlNeutral-Lock
Pivot.................................................................58
HydraulicSystemMaintenance....................................58
ServicingtheHydraulicSystem.................................58
MowerDeckMaintenance...........................................60
LevelingtheMowerDeck........................................60
ServicingtheCuttingBlades.....................................62
RemovingtheMowerDeck.....................................65
ReplacingtheGrassDeector..................................66
Cleaning...................................................................67
CleaningundertheMower.......................................67
CleaningtheSuspensionSystem...............................67
DisposingofWaste.................................................67
Storage........................................................................67
CleaningandStorage..............................................67
Troubleshooting...........................................................69
Schematics...................................................................72
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Safety
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructions,andpayattentionto thesafetyalertsymbol,whichmeansCaution,Warning,or Danger—personalsafetyinstruction.Failuretocomplywith theinstructionsmayresultinpersonalinjuryordeath.
Thismachinewasmanufacturedaccordingtotheappropriate regulatorystandardsineffectatthetimeofmanufacture. Modifyingthismachineinanywaymaycauseittobeoutof compliancewiththosestandardsandwiththeinstructionsin thisOperator’ sManual.Modicationstothismachineshould onlybemadebyeitherthemanufactureroranAuthorized ToroDealer.
Thisproductiscapableofamputatinghandsandfeet.Follow allsafetyinstructionstoavoidseriousinjuryordeath.
Theowner/usercanpreventandisresponsibleforaccidents orinjuriesoccurringtopeople,ordamagetoproperty.
Theadditionofattachmentsmadebyothermanufacturers thatdonotmeetAmericanNationalStandardsInstitute certicationwillcausenoncomplianceofthismachine.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSIstandard B71.4-2012.
Training
•ReadtheOperator'sManualandothertrainingmaterial.
•Iftheoperator(s)ormechanic(s)cannotreadthemanual
language,itistheowner'sresponsibilitytoexplainthis materialtothem.
•Becomefamiliarwiththesafeoperationoftheequipment,
operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateorservice
theequipment.Localregulationsmayrestricttheageof theoperator.
•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtopeople,ordamageto property.
Preparation
•Evaluatetheterraintodeterminewhataccessoriesand
attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.
•Wearappropriateclothingincluding:substantial
slip-resistantfootwear,safetyglasses,andhearing protection.Tiebacklonghairanddonotwearjewelry.
•Inspecttheareawheretheequipmentisused,andremove
allobjectsthatcanbethrownbythemachine.
•Checkthatoperator'spresencecontrols,safetyswitches,
andshieldsareattachedandfunctioningproperly.Donot operatethemachineunlesstheyarefunctioningproperly.
Operation
•Lightningcancausesevereinjuryordeath.Iflightning
isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.
•Donotrunanengineinanenclosedarea.
•Operateonlyinwell-litareas,keepingawayfromholes
andhiddenhazards.
•Ensurethatalldrivesareinneutralandthattheparking
brakeisengagedbeforestartingengine.Starttheengine onlyfromtheoperator’ sposition.
•Makesurethatyouhavegoodfootingwhileusingthis
machine,especiallywhenbackingup.Reducedfooting couldcauseslipping.
•Slowdownanduseextracareonhillsides.Besureto
travelsidetosideonhillsides.Turfconditionscanaffect thestabilityofthemachine.Usecautionwhileoperating neardrop-offs.
•Slowdownandusecautionwhenmakingturnsandwhen
changingdirectionsonslopes.
•Donotraisethemowerdeckwiththebladesrunning.
•DonotoperatethemachinewithoutthePTOshieldor
otherguardssecurelyinplace.Besurethatallinterlocks areattached,adjustedproperly,andfunctioningproperly.
•Donotoperatewiththedischargedeectorraised,
removedoraltered,unlessyouareusingagrasscatcher.
•Donotchangetheenginegovernorsettingoroverspeed
theengine.
•Stopthemachineonlevelground,disengagedrives,
engagetheparkingbrake(ifprovided),shutofftheengine beforeleavingtheoperator'spositionforanyreason, includingemptyingthecatchersoruncloggingthechute.
•Stopthemachineandinspectthebladesafterstriking
objectsorifanabnormalvibrationoccurs.Makethe necessaryrepairsbeforeresumingoperation.
•Keepyourhandsandfeetawayfromthecuttingunit.
•Lookbehindanddownbeforebackinguptoensurea
clearpath.
•Keeppetsandbystandersawayfromanoperating
machine.
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•Slowdownandusecautionwhenmakingturnsand
crossingroadsandsidewalks.Stopthebladesifyouare notmowing.
•Beawareofthemower-dischargedirectionanddonot
pointitatanyone.
MaintenanceandStorage
•Disengagedrives,settheparkingbrake,shutoffthe
engine,andremovethekeyordisconnectspark-plugwire. Waitforallmovementtostopbeforeadjusting,cleaning, orrepairingthemachine.
•Donotoperatethemowerwhentired,ill,orunderthe
inuenceofalcoholordrugs.
•Usecarewhenloadingorunloadingthemachineinto
orfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs,trees,
orotherobjectsthatmayobscurevision.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlinggasoline.Gasolineisextremely ammableandthevaporsareexplosive.
•Extinguishallcigarettes,cigars,pipes,andothersources
ofignition.
•Useonlyanapprovedfuelcontainer.
•Donotremovethefuelcaporaddfuelwiththeengine
running.
•Allowtheenginetocoolbeforefueling.
•Donotfuelthemachineindoors.
•Donotstorethemachineorfuelcontainerwherethere
isanopename,spark,orpilotlight,suchasonawater heateroronotherappliances.
•Donotllcontainersinsideavehicle,onatruck,orona
trailerbedwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.
•Removeequipmentfromthetruckortrailerandfuelit
ontheground.Ifthisisnotpossible,thenaddfuelwith suchequipmentasaportablecontainerratherthanfrom afuel-dispensernozzle.
•Keepthenozzleincontactwiththerimofthefueltank
orcontaineropeningatalltimesuntilfuelingiscomplete.
•Donotuseanozzlelock-opendevice.
•Ifyouspillfuelonclothing,changeyourclothing
immediately.
•Parkthemachineonalevelsurface.
•Cleangrassanddebrisfromthecuttingunit,drives,
mufers,andenginetohelppreventres.
•Cleanupoilorfuelspills.
•Lettheenginecoolbeforestoringthemachine.
•Donotstorefuelnearamesordrainfuelindoors.
•Donotallowuntrainedpersonneltoservicethemachine.
•Usejackstandstosupportcomponentswhenrequired.
•Carefullyreleasepressurefromcomponentswithstored
energy.
•Disconnectthebatteryorremovethespark-plugwire
beforemakinganyrepairs.Disconnectthenegative terminalrstandthepositiveterminallast.Connectthe positiveterminalrstandnegativelast.
•Usecarewhencheckingtheblades.Wraptheblade(s)
orwearthicklypaddedgloves,andusecautionwhen servicingthem.Onlyreplaceblades;donotstraighten orweldthem.
•Keephandsandfeetawayfrommovingparts.Ifpossible,
donotmakeadjustmentswiththeenginerunning.
•Keepallpartsingoodworkingconditionandallhardware
tightened.Replaceallwornordamageddecals.
Hauling
•Usecarewhenloadingorunloadingthemachineintoa
traileroratruck.
•Useafull-widthrampforloadingmachineintoatrailer
oratruck.
•Tiethemachinedownsecurelyusingstraps,chains,cable,
orropes.Bothfrontandrearstrapsshouldbedirected downandoutwardfromthemachine.
•Donotoverllthefueltank.Replacethefuelcapand
tightenitsecurely.
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ToroMowerSafety

ThefollowinglistcontainssafetyinformationspecictoToro productsandothersafetyinformationthatyoumustknow.
Thisproductiscapableofamputatinghandsandfeet,and ofthrowingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass,or, whenequippedwithagrassbagger,forcatchingcutgrass. Anyuseforpurposesotherthanthesecouldprovedangerous totheuserandbystanders.
UsingtheRollover-ProtectionSystem (ROPS)
•TheROPSisanintegralandeffectivesafetydevice.Keep
theROPSintheraisedandlockedpositionandusethe seatbeltwhenoperatingthemachine.
•LowertheROPStemporarilyonlywhenabsolutely
necessary.DonotweartheseatbeltwhentheROPSis foldeddown.
•BeawarethereisnorolloverprotectionwhentheROPS
isinthedownposition.
Service
•Donotstorethemachineorafuelcontainerinsidewhere
thereisanopename,suchasnearawaterheateror furnace.
•Keepthenutsandboltstight,especiallythe
blade-attachmentbolts.
•Neverinterferewiththeintendedfunctionofasafety
deviceorreducetheprotectionprovidedbyasafety device.Checktheirproperoperationregularly.
•Tobestprotectyourinvestmentandmaintainoptimal
performanceofyourToroequipment,countonToro genuineparts.Whenitcomestoreliability ,Torodelivers replacementpartsdesignedtotheexactengineering specicationsofourequipment.Forpeaceofmind,insist onTorogenuineparts.
•Checkbrakeoperationfrequently.Adjustandserviceas
required.
•Becertainthattheseatbeltcanbereleasedquicklyin
theeventofanemergency.
•Checktheareatobemowedandneverfolddownthe
ROPSinareaswherethereareslopes,drop-offs,orwater.
•Checkcarefullyforoverheadclearances(i.e.branches,
doorways,electricalwires)beforedrivingunderany objectsanddonotcontactthem.
•KeeptheROPSinsafeoperatingconditionby
periodicallythoroughlyinspectingfordamageand keepingallmountingfastenerstight.
•ReplaceadamagedROPS.Donotrepairorrevise.
•DonotremovetheROPS.
•AnyalterationstoaROPSmustbeapprovedbythe
manufacturer.
•Donotmowslopesgreaterthan15degrees.
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SlopeIndicator
G011841
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge
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SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.
58-6520
1.Grease
93-7818
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto1 15to149N∙m(85to110 ft-lb).
106-2655
1.Warning—donottouchorapproachmovingbelts;remove theignitionkeyandreadtheinstructionsbeforeservicing orperformingmaintenance.
106-5517
1.Warning—donottouchthehotsurface.
99-8936
1.Machinespeed4.Neutral
2.Fast5.Reverse
3.Slow
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107-3069
1.Warning—thereisnorolloverprotectionwhentherollbaris down.
2.Toavoidinjuryordeathfromarolloveraccident,keepthe rollbarinthefullyraisedandlockedpositionandwear theseatbelt.Lowertherollbaronlywhenabsolutely necessary;donotwearthetheseatbeltwhentherollbaris down.
3.ReadtheOperator'sManual;driveslowlyandcarefully.
110-2068
1.ReadtheOperator'sManual.
112-9028
1.Warning—stayawayfrommovingparts;keepallguardsin place.
114-4466
1.Main(25A)3.Charge(25A)
2.PTO(10A)4.Auxiliary(15A)
110-2067
115-7445
1.Greasepulleysandspindles
2.Maintenanceinterval—50hours
9
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115-9625
1.Parking brake—disengaged
2.Parkingbrake—engaged
116-1716
1.Fuel6.Hourmeter
2.Empty
3.Half
4.Full9.Neutral
5.Battery
7.PTO
8.Parkingbrake
10.Operator-presenceswitch
117-0346
1.Fuelleakhazard—readtheOperator'sManual;donot attempttoremovetherollbar;donotweld,drill,ormodify therollbarinanyway.
116-4858
116-8726
1.ReadtheOperator’sManualforrecommendedhydrooil.
117-3848
1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.
2.Thrownobjecthazard,mower—donotoperatethemachine withoutdeector,dischargecover,orgrasscollection systeminplace.
3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts;keepallguardsandshieldsinplace.
10
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117-3864
1.ReadtheOperator’s
Manual.
1.Fast
2.Variablespeedcontrol
2.Filltobottomofllerneck;
121–7586
3.Slow
4.Powertakeoff(PTO)
126-2055
warning—donotoverll thetank.
1.ReadtheOperator’s
manual
2.Lock
126-4398
3.Unlock
1.Wheellug-nuttorque129N∙m(95ft-lb)(4x)
2.Wheelhub-nuttorque319N∙m(235ft-lb)
3.ReadandunderstandtheOperator’smanualbefore performinganymaintenance,checktorqueafterrst100 hoursthenevery500hoursthereafter.
1.ReadtheOperator's
2.Height-of-cut
Manual.
127-0326
3.Removethekeyfrom theignitionandreadthe Operator'sManualbefore performingmaintenance orservicingthemachine.
11
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BatterySymbols
Someorallofthesesymbolsareonyourbattery .
132-5063
1.Camlock2.Camunlock
1.Explosionhazard
2.Nore,opename,or smoking
3.Causticliquid/chemical burnhazard
4.Weareyeprotection.9.Flusheyesimmediately
5.ReadtheOperator's
Manual.
6.Keepbystandersasafe distancefromthebattery.
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.
8.Batteryacidcancause blindnessorsevereburns.
withwaterandgetmedical helpfast.
10.Containslead;donot discard
Manufacturer'sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
125–9383
1.Checkhydraulicuidevery50operatinghours.3.Checkthetirepressureevery50operatinghours.
2.ReadtheOperator’sManualforinformationonlubricating themachine.
4.ReadtheOperator’sManualbeforeservicingorperforming maintenance.
12
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132-0871
1.Warning—readtheOperator’sManual;donotoperatethe machineunlessyouaretrained;wearhearingprotection.
2.Cuttingandpinchinghazard—keephandsandfeetawayfrom movingparts;keepallguardsandshieldsinplace.
3.Thrownobjecthazard—keepbystandersaway.6.Tippinghazardonslopes—donotuseonslopesnearopen
4.Ramphazard—whenloadingontoatrailer ,donotusedual ramps;onlyuseasingularrampwideenoughforthemachine andthathasaninclinelessthan15degrees;backupthe ramp(inreverse)anddriveforwardofftheramp.
5.Bodilyharmhazard—lookbehindyouwhenmowingin reverse.
water;donotuseonslopesgreaterthan15degrees.
132–5067
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ProductOverview
g029631
4
11
12
13
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g0131 12
1
2
3
4
5
6
25
25
10
15
C
H
ECK
ENG
IN
E
FuelGauge
Thefuelgaugeislocatedwiththehourmeter,andthebars lightupwhentheignitionswitchison(Figure6).
Theindicatorlightappearswhenthefuellevelis low—approximately3.8L(1USgallon)remaininginthe fueltank.
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
Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure4andFigure5).
Figure6
1.Fuelgauge(bars)4.Safety-interlocksymbols
2.Batterylight
3.Hourmeter
5.Low-fuelindicatorlight
HourMeter
Thehourmeterrecordsthenumberofhourstheenginehas operated.Itoperateswhentheengineisrunning.Usethese timesforschedulingregularmaintenance(Figure6).
Safety-InterlockIndicators
Therearesymbolsonthehourmeterandtheyindicatewitha blacktrianglethattheinterlockcomponentisinthecorrect position(Figure6).
Battery-IndicatorLight
WhenyouinitiallyturntheignitionkeytotheRUNposition forafewseconds,thebatteryvoltagedisplaysinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturnedonand whenthechargeisbelowthecorrectoperatinglevel(Figure
5).
Figure5
1.PTOSwitch
2.Throttlecontrol5.Ignitionswitch
3.Malfunction-indicatorlight (MIL)
4.Hour meter/Safety-interlock display/Fuelgauge
6.Fuses
ThrottleControl
ThethrottlecontrolisvariablebetweentheFASTandSLOW positions.
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Page 15
Blade-ControlSwitch(PTO)
Specications
Usetheblade-controlswitch(PTO)toengagetheelectric clutchanddrivethemowerblades.Pulltheswitchupto engagethebladesandrelease.Todisengagetheblades, pushtheblade-controlswitch(PTO)downormovea motion-controlleverintotheNEUTRAL-LOCKposition.
IgnitionSwitch
Thisswitchisusedtostartthemowerengineandhas3 positions:Start,Run,andOff.
Motion-ControlLevers
Usethemotion-controlleverstodrivethemachineforward andreverse,andtoturneitherdirection.
Neutral-LockPosition
UsetheNEUTRAL-LOCKpositionwiththesafety-interlock systemtoengageandtodeterminetheNEUTRALposition.
Fuel-ShutoffValve
Closethefuel-shutoffvalve(undertheseat)when transportingorstoringthemower.
Note:Specicationsanddesignaresubjecttochange withoutnotice.
Width
WithoutDeck
DeectorUp157cm(62inches)
DeectorDown192cm(76inches)
135cm(53inches)
Length
RollBarUp
RollBarDown
211cm(83inches)
215cm(85inches)
Height
RollBarUpRollBarDown
179cm(71inches)127.8cm(50.3inches)
Weight
ModelWeight
74991
587kg(1,295lbs)
ElectronicControlUnitMalfunction IndicatorLight
Theelectroniccontrolunit(ECU)continuouslymonitorsthe operationoftheEFIsystem.
Ifthesystemdetectsaproblemorfault,themalfunction indicatorlight(MIL)illuminates.
TheMIListheredlightlocatedintherightconsolepanel.
IftheMILilluminates,performtheinitialtroubleshooting checks;refertotheMILsectioninTroubleshooting(page69).
Ifthesechecksdonotcorrecttheproblem,furtherdiagnosis andservicingbyanAuthorizedServiceDealerisnecessary.
Attachments/Accessories
AselectionofToroapprovedattachmentsandaccessoriesis availableforusewiththemachinetoenhanceandexpand itscapabilities.ContactyourAuthorizedServiceDealeror Distributororgotowww .Toro.comforalistofallapproved attachmentsandaccessories.
15
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Operation
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan30days
old),unleadedgasolinewithanoctaneratingof87or higher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol(gasohol)
or15%MTBE(methyltertiarybutylether)byvolume isacceptable.EthanolandMTBEarenotthesame. Gasolinewith15%ethanol(E15)byvolumeisnot approvedforuse.Neverusegasolinethatcontains morethan10%ethanolbyvolume,suchasE15 (contains15%ethanol),E20(contains20%ethanol),or E85(containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/orengine damagewhichmaynotbecoveredunderwarranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuelcontainers
overthewinterunlessafuelstabilizerisused.
•Donotaddoiltogasoline.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleased,causingasparkthatcan ignitethegasolinevapors.Areorexplosionfrom gasolinecanburnyouandothersandcandamage property.
•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsideavehicleor onatruckortrailerbed,becauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.
•Whenpractical,removegas-poweredequipment fromthetruckortrailerandrefueltheequipment withitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable containerratherthanfromagasoline-dispenser nozzle.
•Ifyoumustuseagasoline-dispensernozzle, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis6to13 mm(1/4to1/2inch)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.
•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaustsystemin placeandinproperworkingcondition.
WARNING
Gasolineisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditionerbottleopening.
•Avoidcontactwithskin;washoffspillswith soapandwater.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachinetoprovide thefollowingbenets:
•Keepsgasolinefreshduringstorageof90daysorless.
Forlongerstorageitisrecommendedthatthefueltank bedrained.
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuelsystem,
whichcauseshardstarting
Important:Donotusefueladditivescontaining methanolorethanol.
Addthecorrectamountofgasolinestabilizer/conditioner tothegasoline.
Note:Afuelstabilizer/conditionerismosteffective whenmixedwithfreshgasoline.T ominimizethechance
16
Page 17
ofvarnishdepositsinthefuelsystem,usefuelstabilizer atalltimes.
FillingtheFuelTank
1.Parkthemachineonlevelground.
2.Shuttheengineoffandsettheparkingbrake.

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mowerdecks anddrivesystemshavehigherfrictionwhennew,placing additionalloadontheengine.Allow40to50hoursof break-intimefornewmachinestodevelopfullpowerand bestperformance.
3.Cleanaroundthefuel-tankcap.
4.Fillthefueltanktothebottomofthellerneck(Figure
7).
Note:Ensurethatthereisemptyspaceinthetankto allowthegasolinetoexpand.
Note:Donotllthefueltankcompletelyfull.Fillthe fueltanktothebottomofthellerneck.

UsingtheRollover-Protection System(ROPS)

WARNING
Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraised,lockedpositionandusethe seatbelt.
Ensurethattheseatissecuredtothemachine.
WARNING
Thereisnorolloverprotectionwhentherollbaris inthedownposition.
•Lowertherollbaronlywhenabsolutely necessary.
•Donotweartheseatbeltwhentherollbaris inthedownposition.
•Driveslowlyandcarefully.
Figure7

CheckingtheEngine-OilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoCheckingthe
Engine-OilLevel(page38).
•Raisetherollbarassoonasclearancepermits.
•Checkcarefullyforoverheadclearances(i.e., branches,doorways,electricalwires)before drivingunderanyobjects,anddonotcontact them.
Important:Ensurethattheseatissecuredtothe machine.
1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.
2.Pullbothknobsoutandrotatethem90degreessothat theyarenotengaged(Figure8).
3.Lowertherollbartothedownposition(Figure8).
17
Page 18
EnteringtheOperating
g029797
Position
Usethemowerdeckasasteptogetintotheoperating position(Figure9).
Figure9
1.Mowerdeck
Figure8
1.ROPSknob
2.PulltheROPSknobout androtateit90degrees.
4.Toraisetherollbar,raisetherollbartotheoperate positionandrotatetheknobssothattheymove partiallyintothegrooves(Figure8).
5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarsothatthepinssnapinto positionwhentheholesalignwiththepins(Figure8).
6.Pushontherollbarandensurethatbothpinsare engaged.
Important:Alwaysusetheseatbeltwiththerollbarin theraisedposition.
3.Rollbarintheupright position
4.Rollbarinthefolded position

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthesafety section.Knowingthisinformationcouldhelpyouor bystandersavoidinjury.
DANGER
Operatingthemachineonwetgrassorsteepslopes cancauseslidingandlossofcontrol.
•Donotoperateonslopesgreaterthan15degrees.
•Reducespeedanduseextremecautionon slopes.
•Donotoperatethemachinenearwater.
DANGER
Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,death,or drowning.
Donotoperatethemachineneardrop-offs.
DANGER
Operatingthemachinewhiletherollbarisdown mayleadtoseriousinjuryordeathintheeventofa rollover.
Alwayskeeptherollbarinthefullyraisedand lockedpositionandusetheseatbelt.
18
Page 19
Figure10
G009027
1
2
g029632
g029829

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor leaveitunattended.
SettingtheParkingBrake
WARNING
Theparkingbrakemaynotholdamachineparked onaslopeandcouldcausepersonalinjuryor propertydamage.
Donotparkthemachineonslopesunlessthe wheelsarechockedorblocked.
1.SafeZone—usethe machinehereonslopes lessthan15degreesor atareas.
2.DangerZone—usea walk-behindmowerand/or ahandtrimmeronslopes greaterthan15degrees, neardrop-offsandwater.
3.Water
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator’searandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Useprotectiveequipmentforyoureyes,ears,hands,feet, andhead.
Figure12
ReleasingtheParkingBrake
Figure11
1.Weareyeprotection.2.Wearhearingprotection.
19
Figure13
Page 20
OperatingtheMower
G008945
G009174
G008946
START
RUN
STOP
G008947
G008948
1
2

OperatingtheIgnitionSwitch

Blade-ControlSwitch(PTO)
Theblade-controlswitch(PTO)startsandstopsthemower bladesandanypoweredattachments.
EngagingtheBlade-ControlSwitch (PTO)
Note:Engagingtheblade-controlswitch(PTO)withthe
throttlepositionathalforlesscausesexcessiveweartothe drivebelts.
Figure14
1.TurntheignitionkeytotheSTARTposition(Figure17).
Note:Whentheenginestarts,releasethekey.
Important:Donotengagethestarterformore
than5secondsatatime.Iftheenginefailsto start,wait15secondsbetweenattempts.Failureto followtheseinstructionscanburnoutthestarter motor.
Note:Youmayneedmultipleattemptstostartthe enginewhenyoustartitthersttimeafterthefuel systemhasbeenwithoutfuelcompletely.
Figure17
DisengagingtheBlade-ControlSwitch (PTO)
2.TurntheignitionkeytotheSTOPpositiontoshutoff theengine.

UsingtheFuel-ShutoffValve

Thefuel-shutoffvalveislocatedundertheseat.Movethe seatforwardtoaccessit.
Closethefuel-shutoffvalvefortransport,maintenance,and
Figure15
storage.
Ensurethatthefuel-shutoffvalveisopenwhenstartingthe engine.

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweenFASTandSLOW positions(Figure16).
AlwaysusetheFASTpositionwhenturningonthemower deckwiththeblade-controlswitch(PTO).
Figure18
Figure16
1.On2.Off
20
Page 21
StartingandShuttingOffthe
START
RUN
STOP
G008947
g029635
A B
C D
E
Engine
StartingtheEngine
1.RaisetheROPSup,lockitintoplace,sitontheseat, andfastentheseatbelt.
2.Movethemotion-controlleverstotheNEUTRAL-LOCK position.
3.Settheparkingbrake;refertoSettingtheParking
Brake(page19).
4.Movetheblade-controlswitch(PTO)totheOFF position(Figure19).
Figure20
1.Off3.Start
2.Run
5.MovethethrottlelevermidwaybetweentheSLOWand FASTpositions.
ShuttingOfftheEngine
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
6.TurntheignitionkeytotheSTARTposition(Figure20).
Note:Whentheenginesstarts,releasethekey.
Important:Donotengagestarterformorethan5
secondsatatime.Iftheenginefailstostart,wait 15secondsbetweenattempts.Failuretofollow theseinstructionscanburnoutthestartermotor.
Note:Youmayneedtoattempttostarttheengine multipletimeswhenyoustartitforthersttimeafter thefuelsystemhasbeenwithoutfuelcompletely.
Figure19
Figure21
21
Page 22
Important:Makesurethatyouclosethefuel-shutoff
G009181
1
valvebeforetransportingorstoringthemachine,as fuelleakagemayoccur.Settheparkingbrakebefore transportingthemachine.Makesuretoremovethekey asthefuelpumpmayrunandcausethebatterytolose charge.
TestingtheSafety-InterlockSystem
ServiceInterval:Beforeeachuseordaily
Testthesafety-interlocksystembeforeyouusethemachine eachtime.Ifthesafetysystemdoesnotoperateasdescribed below,haveanAuthorizedServiceDealerrepairthesafety systemimmediately.

UsingtheSafety-Interlock System

CAUTION
Ifthesafety-interlockswitchesaredisconnectedor damaged,themachinecouldoperateunexpectedly, causingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
UnderstandingtheSafety-Interlock System
Thesafety-interlocksystemisdesignedtopreventtheengine fromstartingunless:
•Theparkingbrakeisengaged.
•Theblade-controlswitch(PTO)isdisengaged.
•Themotion-controlleversareintheNEUTRAL-LOCK
position.
Thesafety-interlocksystemalsoisdesignedtoshutoffthe enginewhenyoumovethetractioncontrolsfromthelocked positionwiththeparkingbrakeengagedorifyourisefrom theseatwhenthePTOisengaged.
1.Sitontheseat,engagetheparkingbrakeandmovethe blade-controlswitch(PTO)totheONposition.Try startingtheengine;theengineshouldnotcrank.
2.Sitontheseat,engagetheparkingbrakeandmovethe blade-controlswitch(PTO)totheOFFposition.Move eithermotion-controllever(outoftheNEUTRAL-LOCK position).Trystartingtheengine;theengineshould notcrank.Repeatfortheothercontrollever.
3.Sitontheseat,engagetheparkingbrake,movethe blade-controlswitch(PTO)totheOFFposition,and movethemotion-controlleverstotheNEUTRAL-LOCK position.Starttheengine.Whiletheengineisrunning, releasetheparkingbrake,engagetheblade-control switch(PTO),andriseslightlyfromtheseat;theengine shouldshutoff.
4.Sitontheseat,engagetheparkingbrake,movethe blade-controlswitch(PTO)totheOFFposition,and movethemotion-controlleverstoNEUTRAL-LOCK position.Starttheengine.Whiletheengineisrunning, centereithermotion-controlleverandmoveitforward orreverse;theengineshouldshutoff.Repeatforthe othermotion-controllever.
5.Sitontheseat,disengagetheparkingbrake,movethe blade-controlswitch(PTO)totheOFFposition,and movethemotion-controlleverstoNEUTRAL-LOCK position.Trystartingtheengine;theengineshould notcrank.
Thehourmeterhassymbolstonotifyyouwhenthe interlockcomponentisinthecorrectposition.Whenthe componentisinthecorrectposition,atrianglelightsupin thecorrespondingsquare.
Figure22
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition.
22
Page 23

DrivingForwardorBackward

G008952
DrivingForward
Thethrottlecontrolregulatestheenginespeedasmeasured inrpm(revolutionsperminute).Placethethrottlecontrolin theFASTpositionforbestperformance.Alwaysoperatein thefullthrottlepositionwhenmowing.
CAUTION
Machinecanspinveryrapidly.Youmaylose controlofmachineandinjureyourselfordamage themachine.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemakingsharp turns.
UsingtheMotion-ControlLevers
Note:Theengineshutsoffifyoumovethetraction-control
leverswiththeparkingbrakeengaged.
Tostop,pullthemotion-controlleverstotheNEUTRAL position.
1.Releasetheparkingbrake;refertoReleasingthe
ParkingBrake(page19).
2.Movetheleverstothecenter,unlockedposition.
3.Togoforward,slowlypushthemotion-controllevers forward(Figure24).
Figure23
1.Motion-control lever—NEUTRAL-LOCK position
2.Center,unlockedposition5.Frontofmachine
3.Forward
4.Backward
Figure24
23
Page 24
DrivingBackward
G008953
1.Movetheleverstothecenter,unlockedposition.
2.Togobackward,slowlypullthemotion-controllevers rearward(Figure25).
Figure25

ShuttingOfftheMachine

Toshutoffthemachine,movethemotion-controlleversto neutralandthentotheNEUTRAL-LOCKposition,disengage theblade-controlswitch(PTO),andturntheignitionkeyto theOFFposition.
Settheparkingbrakewhenyouleavethemachine;referto
SettingtheParkingBrake(page19).Removethekeyfrom
theignitionswitch.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

AdjustingtheHeightofCut

UsingtheTransportLock
Thetransportlockhas2positions,andisusedwiththe deck-liftpedal.ThereisaLOCKpositionandanUNLOCK positionforthetransportpositionofthemowerdeck(Figure
26).
Figure26
Transport-LockPositions
1.Transportlock3.UNLOCKposition—The mowerdeckdoesnotlock intothetransportposition.
2.LOCKposition—The
mowerdecklocksintothe transportposition.
24
Page 25
AdjustingtheHeight-of-CutPin
g029955
g029956
AdjustingtheAnti-Scalp
Adjusttheheight-of-cutfrom25to140mm(1to5-1/2 inches)in6mm(1/4inch)incrementsbymovingtheclevis pinintodifferentholelocations.
1.MovethetransportlocktotheLOCKposition.
2.Pushonthedeck-liftpedalwithyourfootandraisethe mowerdecktotheTransportposition(alsothe140 mmor5-1/2inchcutting-heightposition)asshown inFigure26.
3.Toadjust,rotatethepin90degreesandremovethepin fromtheheight-of-cutbracket(Figure27).
4.Selectaholeintheheight-of-cutbracketcorresponding totheheight-of-cutdesired,andinsertthepin(Figure
27).
5.Pushonthedecklift,pullbackonthetransportlock, andslowlylowerthemowerdeck.
Rollers
Wheneveryouchangetheheightofcut,adjusttheheight oftheanti-scalprollers.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
Figure28
1.Deck-liftpedal
2.Height-of-cutpin
Figure27
3.Transportlock
1.Anti-scalproller4.Flangenut
2.Spacer
3.Bushing
1.Anti-scalproller3.Flangenut
2.Bushing4.Bolt
5.Bolt
Figure29
25
Page 26
AdjustingtheFlow-Bafe-Cam
PositioningtheFlowBafe
Locks
ForMachineswithFlow-BafeLocks Only
Youcanadjustthemower-dischargeowfordifferenttypes ofmowingconditions.Positionthecamlocksandbafeto achievethebestqualityofcut.
Note:Certainmodelshavenutsandboltsinplaceofthe ow-bafelocks.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthecamlocks,swingtheleveruptoloosen thecamlock(Figure30).
4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow.
5.Swingtheleverbackovertotightenthebafeandcam locks(Figure30).
Thefollowingguresareonlyrecommendationsforuse. Adjustmentsvarybygrasstype,moisturecontent,andheight ofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition.Usethispositionforthe following.
•Short,lightgrassmowingconditions.
•Dryconditions.
•Smallergrassclippings.
•Propellinggrassclippingsfartherawayfromthemower.
6.Ifthecamlocksdonotlockthebafeintoplaceorit istootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilyouachievethedesired lockingpressure.
Figure30
Figure31
26
Page 27
PositionB
g029830
g030021
Usethispositionwhenbagging.Alwaysalignitwiththe bloweropening.
Figure32

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positiontheseat whereyouhavethebestcontrolofthemachineandaremost comfortable.
Toadjusttheseat,movetheleversidewaystounlockseat (Figure34).
Figure34
PositionC
Thisisthefullyopenposition.Usethispositionforthe following:
•Tall,densegrassmowingconditions.
•Wetconditions.
•Loweringtheenginepowerconsumption.
•Increasedgroundspeedinheavyconditions.

UnlatchingtheSeat

Figure35
Figure33
Note:ThispositionissimilartothebenetsoftheToro
SFSmower.
27
Page 28
AdjustingtheMyRide™
A
C
D
g030019
B
SuspensionSystem
TheMyRide™suspensionsystemadjuststoprovidea smoothandcomfortableride.Adjustingtherear2-shock assembliesistheeasiestandquickestadjustmentforchanging thesuspensionsystem.Positionthesuspensionsystemwhere youaremostcomfortable.
AdjustingtheRear-ShockAssemblies
Theslotsfortherear-shockassemblieshavedetentpositions forreference.Youcanpositiontherear-shockassemblies anywhereintheslot,notjustinthedetentpositions.
Thefollowinggraphicshowsthepositionforasoftorrm rideandthedifferentdetentpositions(Figure36).
Adjusttherear-shockassemblies(Figure37).
Figure36
1.Firmestposition3.Detentsintheslots
2.Softestposition
Note:Ensurethattheleftandrightrear-shockassemblies arealwaysadjustedtothesamepositions.
Figure37
28
Page 29
AdjustingtheFront-ShockAssembly
g029831
Thefront-shockassemblyissetatthemiddlepositionandis normallynotadjusted.
Toadjustthefront-shockassembly,opentheoorpanand adjustitbyusingaspannerwrench(ToroPartNo.132-5069) orslip-jointpliers(Figure38).
Figure38
1.Disengagetheblade-controlswitch(PTO)and turntheignitionkeytooff.Movetheleverstothe NEUTRAL-LOCKpositionandapplytheparkingbrake. Removethekey.
2.Rotatetherelease-valveleversverticallytopushthe machine(Figure39).
Note:Thisallowsthehydraulicuidtobypassthe pump,enablingthewheelstoturn.
3.Disengagetheparkingbrakebeforepushingthe machine.
1.Middleposition
2.Firmride
3.Softride

UsingtheDrive-WheelRelease Valves

WARNING
Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury.
Shutofftheengine,removethekey,andwait forallmovingpartstostopbeforeaccessingthe drive-wheelreleasevalves.
WARNING
Theengineandhydraulicdriveunitscanbecome veryhot.Touchingahotengineorhydraulicdrive unitscancausesevereburns.
Waitfortheengineandhydraulicdriveunitstocool completelybeforeaccessingthedrive-wheelrelease valves.
Thedrive-wheelreleasevalvesarelocatedinthebackofeach hydraulicdriveunit,undertheseat.
Note:Makesurethatthereleasevalvesareinthefully horizontalpositionwhenoperatingthemachine,orsevere damagetothehydraulicsystemcouldoccur.
Figure39
1.Verticaltopushthe machine
4.Rotatetherelease-valvelevershorizontallytorunthe machine(Figure39).
2.Horizontaltorunthe machine

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
DANGER
Withoutagrassdeector,dischargecover,ora completegrass-catcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriscauseinjuryordeath.
•Neverremovethegrassdeectorfromthemower becausethegrassdeectorroutesmaterialdown towardtheturf.Ifthegrassdeectorisever damaged,replaceitimmediately .
•Neverputyourhandsorfeetunderthemower.
•Nevertrytoclearthedischargeareaormower bladesunlessyoumovetheblade-controlswitch (PTO)totheOFFposition,rotatetheignition keytotheOFFposition,andremovethekey.
•Makesurethatthegrassdeectorisinthedown position.
29
Page 30

TransportingtheMachine

g029641
g028043

LoadingtheMachine

Useaheavy-dutytrailerortrucktotransportthemachine. Ensurethatthetrailerortruckhasallnecessarybrakes, lighting,andmarkingasrequiredbylaw .Pleasecarefullyread allthesafetyinstructions.Knowingthisinformationcould helpyou,yourfamily,pets,orbystandersavoidinjury.
WARNING
Drivingonthestreetorroadwaywithout turnsignals,lights,reectivemarkings,ora slow-moving-vehicleemblemisdangerousandcan leadtoaccidents,causingpersonalinjury.
Donotdrivethemachineonapublicstreetor roadway.
1.Ifyouareusingatrailer,connectittothetowing vehicleandconnectthesafetychains.
2.Ifapplicable,connectthetrailerbrakes.
3.Loadthemachineontothetrailerortruck.
4.Shutofftheengine,removethekey,setthebrake,and closethefuelvalve.
5.Usethemetaltie-downloopsonthemachineto securelyfastenittothetrailerortruckwithstraps, chains,cable,orropes(Figure40).
Useextremecautionwhenloadingortheunloadingmachine ontoatraileroratruck.Useafull-widthrampthatiswider thanthemachineforthisprocedure.Backthemachineupthe rampanddriveitforwarddowntheramp(Figure41).
Figure41
1.Backthemachineupthe ramp.
Important:Donotusenarrowindividualrampsfor eachsideofthemachine.
Ensurethattherampislongenoughsothattheanglewith thegrounddoesnotexceed15degrees(Figure42).Onat ground,thisrequiresaramptobeatleast4timesaslongas theheightofthetrailerortruckbedtotheground.Asteeper anglemaycausemowercomponentstogetcaughtasthe machinemovesfromtheramptothetrailerortruck.Steeper anglesmayalsocausethemachinetotiporlosecontrol.If youareloadingthemachineonornearaslope,positionthe trailerortrucksothatitisonthedownsideoftheslopeand therampextendsuptheslope.Thisminimizestheramp angle.
2.Drivethemachineforward downtheramp.
1.Tie-downloops
Figure40
30
Page 31
WARNING
g027996
5
1
2
6
Loadingamachineontoatrailerortruckincreases thepossibilityofatip-overandcouldcauseserious injuryordeath.
•Useextremecautionwhenoperatingamachine onaramp.
•EnsurethattheROPSisintheuppositionand usetheseatbeltwhenloadingorunloadingthe machine.EnsurethattheROPSclearsthetop ofanenclosedtrailer.
•Useonlyafull-widthramp;donotuseindividual rampsforeachsideofthemachine.
•Donotexceeda15-degreeanglebetweenthe rampandthegroundorbetweentherampand thetrailerortruck.
•Ensurethatthelengthoframpisatleast4times aslongastheheightofthetrailerortruckbedto theground.Thisensuresthatrampangledoes notexceed15degreesonatground.
•Backthemachineuptherampanddriveit forwarddowntheramp.
•Avoidsuddenaccelerationordecelerationwhile drivingthemachineonarampasthiscould causealossofcontroloratip-over.
1.Full-widthrampinstowed position
2.Sideviewoffull-width rampinloadingposition
3.Notgreaterthan 15degrees
Figure42
4.Therampisatleast4 timesaslongastheheight ofthetrailerortruckbed totheground.
5.H=heightofthetraileror truckbedtotheground
6.Trailer
31
Page 32
OperatingTips
UsingtheFastThrottleSetting
Forbestmowingandmaximumaircirculation,operate theengineattheFASTthrottleposition.Airisrequiredto thoroughlycutgrassclippings,sodonotsettheheightof cutsolowastototallysurroundthemowerinuncutgrass. Alwaystrytohave1sideofthemowerfreefromuncutgrass, whichallowsairtobedrawnintothemower.
CuttingaLawnfortheFirstTime
Cutthegrassslightlylongerthannormaltoensurethat thecuttingheightofthemowerdoesnotscalpanyuneven ground.However,thecuttingheightyouhaveusedinthe pastisgenerallythebesttouse.Whencuttinggrasslonger than15cm(6inches)tall,youmaywanttocutthelawntwice toensureanacceptablequalityofcut.
CuttingaThirdoftheGrassBlade
CuttingLongGrass
Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raisethe cuttingheighthigherthanusualandcutthegrassatthis setting.Thencutthegrassagainusingthelower,normal setting.
Stopping
Ifyoumuststoptheforwardmotionofthemachinewhile mowing,aclumpofgrassclippingsmaydropontoyourlawn. Toavoidthis,moveontoapreviouslycutareawiththeblades engaged.
KeepingtheUndersideoftheMower Clean
Cleanclippingsanddirtfromtheundersideofthemower aftereachuse.Ifgrassanddirtbuildupinsidethemower,the cuttingqualityeventuallybecomesunsatisfactory.
Itisbesttocutonlyaboutathirdofthegrassblade.Cutting morethanthatisnotrecommendedunlessgrassissparse,or itislatefallwhengrassgrowsmoreslowly.
AlternatingtheMowingDirection
Alternatethemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippings,whichenhances decompositionandfertilization.
MowingatCorrectIntervals
Normally,mowevery4days.However,grassgrowsat differentratesatdifferenttimes.Tomaintainthesamecutting height,whichisagoodpractice,mowmoreofteninearly spring.Asthegrassgrowthrateslowsinmid-summer,mow lessfrequently .Ifyoucannotmowforanextendedperiod, rstmowatahighcuttingheight;thenmowagain2days lateratalowerheightsetting.
AdjustingtheCuttingSpeed
Toimprovecutquality,useaslowergroundspeedincertain conditions.
MaintainingtheBlade
Maintainasharpbladethroughoutthecuttingseason,because asharpbladecutscleanlywithouttearingorshreddingthe grassblades.Tearingandshreddingturnsgrassbrownat theedges,whichslowsgrowthandincreasesthechanceof disease.Checkthecutterbladesdailyforsharpnessandfor anywearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn,replaceit immediatelywithagenuineT ororeplacementblade.
AvoidingCuttingTooLow
Ifthecuttingwidthofthemoweriswiderthanthemower thatyoupreviouslyused,raisethecuttingheighttoensure thatuneventurfisnotcuttooshort.
32
Page 33
Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst100hours
Aftertherst250hours
Beforeeachuseordaily
Every50hours
Every100hours
MaintenanceProcedure
•Checkthewheellug-nuttorque.
•Checkthewheelhubslotted-nuttorque.
•Checktheparking-brakeadjustment(checkeverytimeyouremoveorreplacea brakecomponent).
•Changethehydraulicltersandhydraulicuid.
•Checkthesafetysystem.
•Checktheengine-oillevel.
•Checktheseatbelt.
•Checktherollover-protection-system(ROPS)knobs.
•Cleantheenginescreenandtheoilcooler.
•Cleanthehydraulicunits.
•Inspecttheblades.
•Cleanthemowerdeck.
•Greasethemower-deckspindlesandidlerarm.
•Checksparkarrester(ifequipped).
•Checkthetirepressure.
•Inspectthebeltsforcracksandwear.
•Checkthehydraulic-uidlevel.
•Lubricatethemowerdeckliftpivots.
•Changetheengineoil(moreoftenindirtyordustyconditions).
•Checkandcleantheenginecoolingnsandshrouds.
Every150hours
Every200hours
Every250hours
Every300hours
Every500hours
Every600hours
Yearlyorbeforestorage
•Inspecttheprimarylterandair-inletscreen.
•Changetheengineoillter(moreoftenindirtyordustyconditions).
•Cleantheengineoilcooler.
•Check,cleanandgapthesparkplug.
•Replacethefuellter(moreoftenindirtyordustyconditions).
•ChangethehydraulicltersandhydraulicuidwhenusingMobil®1uid(more oftenindirtyordustyconditions).
•Replacetheprimaryairlter(moreoftenindustyorsandyconditions).
•Checktheinnerairlter.
•Checkthewheellug-nuttorque.
•Checkthewheelhubslotted-nuttorque.
•Adjustthecaster-pivotbearing.
•Checktheparking-brakeadjustment.
•ChangethehydraulicltersandhydraulicuidwhenusingToro®HYPR-OIL™500 hydraulicuid(moreoftenindirtyordustyconditions).
•Replacetheinnerairlter.
Monthly
Yearly
•Checkthebattery .
•Greasethepump-beltidlerarm.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Repackthefrontcaster-wheelbearings(moreoftenindirtyordustyconditions).
•Lubricatethecaster-wheelhubs.
•Paintchippedsurfaces.
•Checkallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.
33
Page 34
CAUTION
g029642
G017050
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
Lubrication
Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy.
GreaseType:No.2lithiumormolybdenum-basegrease
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.
Note:Makesuretoscrapeanypaintoffthefrontof thetting(s).
4.Connectagreaseguntothettingandpumpgrease intothettingsuntilgreasebeginstooozeoutofthe bearings.
5.Wipeupanyexcessgrease.

AddingLightOilorSpray Lubrication

ServiceInterval:Every100hours
Lubricatethedeckliftpivots.
Figure43
Figure44
34
Page 35

GreasingtheMower

G009029
g029643
ServiceInterval:Every50hours—Greasethemower-deck
spindlesandidlerarm.
Yearly—Greasethepump-beltidlerarm.
Yearly—Greasethefrontcasterpivots(moreoftenin dirtyordustyconditions).
Yearly—Repackthefrontcaster-wheelbearings(more oftenindirtyordustyconditions).
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
5.Greasethedrive-beltidlerarm(Figure45).
3.Greasethemower-deckidler-pulleypivotuntilgrease comeoutthebottom(Figure45).
4.Greasethe3spindlebearingsuntilgreasecomesout thelowerseals(Figure45).
Figure45
Figure46
6.Removethedustcapandadjustthecasterpivots.
Note:Keepthedustcapoffuntilgreasingiscomplete. RefertoAdjustingtheCaster-PivotBearing(page49).
7.Removethehexplugandthreadagreasettinginto thehole.
8.Pumpgreaseintothettinguntilitoozesoutaround thetopbearing.
9.Removethegreasettingfromthehole.
10.Installthehexpluganddustcap(Figure47).
Figure47
35
Page 36

LubricatingtheCaster-Wheel Hubs

ServiceInterval:Yearly
1.Shutofftheengine,waitforallmovingpartstostop, removethekey,andengagetheparkingbrake.
Figure48
14.Torquethenutto8to9N∙m(75to80in-lb),loosen thenut,thentorqueitto2to3N∙m(20to25in-lb).
Note:Makesurethattheaxledoesnotextendbeyond eithernut.
15.Installthesealguardsoverthewheelhubandinsert wheelintothecasterfork.
16.Installthecasterboltandtightenthenutfully.
Important:T opreventsealandbearingdamage,check thebearingadjustmentoften.Spinthecastertire.The tireshouldnotspinfreely(morethan1or2revolutions) orhaveanysideplay .Ifthewheelspinsfreely,adjustthe torqueonthespacernutuntilthereisaslightamountof drag.Applyanotherlayerofthread-lockingcompound.
1.Sealguard2.Spacernutwithwrench
2.Removethecasterwheelfromthecasterforks.
3.Removethesealguardsfromthewheelhub.
4.Removeaspacernutfromtheaxleassemblyinthe casterwheel.
Note:Thread-lockingcompoundhasbeenappliedto lockthespacernutstotheaxle.
5.Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly .
6.Pryoutsealsandinspectbearingsforwearordamage andreplaceifnecessary.
7.Packthebearingswithageneral-purposegrease.
8.Insert1bearingand1newsealintothewheel.
Note:Replacetheseals.
9.Ifbothspacernutshavebeenremoved(orbroken loose)fromtheaxleassembly,applyathread-locking compoundto1spacernutandthreaditontotheaxle withthewrenchatsfacingoutward.
ats
Note:Donotthreadthespacernutalloftheway ontotheendoftheaxle.Leaveapproximately3mm (1/8inch)fromtheoutersurfaceofthespacernutto theendoftheaxleinsidethenut.
10.Inserttheassemblednutandaxleintothewheelonthe sidewiththenewsealandbearing.
11.Withtheopenendofthewheelfacingup,llthearea insidethewheelaroundtheaxlefullofgeneral-purpose grease.
12.Insertthesecondbearingandnewsealintothewheel.
13.Applyathread-lockingcompoundtothesecondspacer nutandthreaditontotheaxlewiththewrenchats facingoutward.
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EngineMaintenance
g030481
1
2
3
4
5
6
7
6.Releasethelatchesontheaircleanerandpullthe air-cleanercoverofftheair-cleanerbody(Figure49).
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothing,andotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every150hours
Every300hours/Yearly(whichevercomes rst)—Replacetheprimaryairlter(moreoftenin dustyorsandyconditions).
Every300hours—Checktheinnerairlter.
Every600hours—Replacetheinnerairlter.
Note:Checktheltersmorefrequentlyiftheoperating conditionsareextremelydustyorsandy.
RemovingtheFilters
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasethelatchesontheaircleanerandpullthe air-inletcoverofftheair-cleanerbody(Figure49).
7.Cleantheinsideoftheair-cleanercoverwith compressedair.
8.Gentlyslidetheprimarylteroutoftheair-cleaner body(Figure49).
Note:Avoidknockingthelterintothesideofthe body.
9.Removetheinnerlteronlyifyouintendtoreplaceit.
Important:Neverattempttocleantheinnerlter. Ifthesafetylterisdirty,thentheprimarylteris damaged;replacebothlters.
10.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutsideof thelter.
Note:Anyholesinthelterappearasbrightspots. Ifthelterisdamaged,discardit.
ServicingthePrimaryFilter
•Iftheprimarylterisdirty,bent,ordamaged,replaceit.
•Donotcleantheprimarylter.
ServicingtheSafetyFilter
Replacethesafetylter,nevercleanit.
Important:Neverattempttocleanthesafetylter. Ifthesafetylterisdirty,thentheprimarylteris damaged.Replacebothlters.
4.Cleantheair-inletscreenandcover.
5.Installtheair-inletcoverandsecureitwiththelatches (Figure49).
Figure49
1.Cover
2.Primarylter6.Cover
3.Innerlter
4.Air-cleanerbody
5.Air-inletscreen
7.Latch
InstallingtheFilters
Important:Topreventenginedamage,alwaysoperate
theenginewithbothairltersandthecoverinstalled.
1.Ifyouareinstallingnewlters,checkeachlterfor shippingdamage.
Note:Donotuseadamagedlter.
2.Ifyouarereplacingtheinnerlter,carefullyslideitinto thelterbody(Figure49).
3.Carefullyslidetheprimarylterovertheinnerlter (Figure49).
Note:Ensurethattheprimarylterisfullyseatedby pushingonitsouterrimwhileinstallingit.
Important:Donotpressonthesoftinsidearea ofthelter.
4.Installtheair-cleanercoverandsecurethelatches (Figure49).
37
Page 38

ServicingtheEngineOil

G029644
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OilType:Detergentoil(APIserviceclassSL,SM,SN,or higher)
OilCapacity:withalterchange,1.9L(2.0USqt);withno lterchange,1.6L(1.7USqt)
Viscosity:Seethetablebelow.
Figure50
Note:Useofsyntheticoilhaving5W-20or5W-30ratingis
acceptable,upto4degreesC(40degreesF).
Note:Syntheticoilswillprovidebetterstartinginextreme coldbelow-23degreesC(-10degreesF).
CheckingtheEngine-OilLevel
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.
Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donotrun enginewithoilbelowthelowmarkbecausetheengine maybedamaged.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
Figure51
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure51).
38
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ChangingtheEngineOil
G029644
B
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D
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g027660
ServiceInterval:Every100hours(moreoftenindirtyor
dustyconditions).
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunfor5minutes.
Note:Thiswarmstheoilsothatitdrainsbetter.
2.Parkthemachinesothattherearisslightlylowerthan thefronttoensurethattheoildrainscompletely.
3.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
4.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position(Figure52).
5.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloilto bringittotheFullmark(Figure53).
Figure53
6.Starttheengineanddrivetoaatarea.Checktheoil levelagain.
Figure52
39
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ChangingtheEngine-OilFilter
G029644
B
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g027477
G029644
g01301 1
1 2
2
ServicingtheEngine-OilCooler
ServiceInterval:Every200hours(moreoftenindirtyor
dustyconditions).
Note:Changetheengineoilltermorefrequentlywhen operatingconditionsareextremelydustyorsandy.
1.Draintheoilfromtheengine;refertoChangingthe
EngineOil(page39).
2.Changetheengineoillter(Figure54).
ServiceInterval:Every200hours
1.Keeptheoilcoolerfreeofdebrisbycleaningthens withabrush.
2.Removetheboltsholdingtheoilcoolertotheengine housing.
3.Cleantheinsideoftheoilcoolerwithabrush.
4.Installtheoilcoolertotheenginehousing.
Note:Ensuretheoilltergaskettouchestheengine andthenanextra3/4turniscompleted.
3.Fillthecrankcasewiththepropertypeofnewoil;refer toChangingtheEngineOil(page39).
Figure54
Figure55
1.Engine-oilcooler2.Bolts

ServicingtheSparkPlug

ServiceInterval:Every200hours—Check,cleanandgap
thesparkplug.
Makesurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug.Usea sparkplugwrenchtoremoveandinstallthesparkplug(s)and useagappingtool/feelergaugetocheckandadjusttheair gap.Installanewsparkplug(s)ifnecessary.
Type:Champion
AirGap:0.76mm(0.030inch)
®
XC12YC,orequivalent
40
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RemovingtheSparkPlug
g029645
g029646
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1.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
2.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
3.Removethelefthydraulicunitshroudintheorder listedwithFigure56.
Note:Thisgivesyouaccesstothefrontsparkplug.
Figure57
5.Installthelefthydraulicunitshroud(Figure56).
CheckingtheSparkPlug
Important:Replacethesparkplug(s)whenithas:a
blackcoating,wornelectrodes,anoilylm,cracksor reuseisquestionable.
Figure56
1.Pullthistabouttothe sideinthedirectionofthe arrow.
2.Pulltheshroudoffthis frametabinthedirection ofthearrow.
4.Removethesparkplug(Figure57).
3.Pulltheshroudoffthis
4.Shroud
Ifyouseelightbrownorgrayontheinsulator,theengineis operatingproperly .Ablackcoatingontheinsulatorusually meanstheaircleanerisdirty.
Setthegapto0.76mm(0.030inches).
Figure58
frametabinthedirection ofthearrow.
41
Page 42
InstallingtheSparkPlug
Tightenthesparkplug(s)to24.4to29.8N∙m(18to22ft-lb).
FuelSystem Maintenance
WARNING
Fuel-systemcomponentsareunderhighpressure. Theuseofimpropercomponentscanresultin systemfailure,gasolineleakage,andpossible explosion.
Useonlyapprovedfuellinesandfuellters.

ServicingtheElectronic Fuel-InjectionSystem

Thismachinecontainsanelectronicfuel-injectionsystem.It controlsthefuelowunderdifferentoperatingconditions.
Figure59

CheckingtheSparkArrester (ifEquipped)

ServiceInterval:Every50hours
WARNING
Hotexhaustsystemcomponentsmayignite gasolinevaporsevenafteryoushutofftheengine. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresultin personalinjuryorpropertydamage.
Donotrefuelorruntheengineunlessaspark arresterisinstalled.
1.Shutofftheengine,waitforallmovingpartstostop, andremovekey.Engageparkingbrake.
2.Waitforthemufertocool.
3.Ifthereareanybreaksinthescreenorwelds,replace thearrester.
4.Ifthescreenisplugged,removethearresterand shakethelooseparticlesoutofthearresterandclean thescreenwithawirebrush(soakitinsolventif necessary).Installthearresterontheexhaustoutlet.
Theelectroniccontrolunit(ECU)continuouslymonitorsthe operationoftheEFIsystem.
Ifaproblemorfaultwithinthesystemisdetected,the malfunctionindicatorlight(MIL)illuminates.TheMIListhe redlightlocatedintherightconsolepanel.
OncetheMILilluminates,makeinitialtroubleshooting checks.RefertotheMILsectionunderTroubleshooting
(page69).
Ifthesechecksdonotcorrecttheproblem,furtherdiagnosis andservicingbyanAuthorizedServiceDealerisnecessary.

ReplacingtheLow-Pressure FuelFilter

ServiceInterval:Every200hours/Yearly(whichevercomes
rst)
Thefuellterislocatedneartheengineonthefrontorrear sideoftheengine.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Waitforthemachinetocooldown.
4.Closethefuel-shutoffvalveundertheseat(Figure60).
42
Page 43
G008963
12
3
1.Fuellter
2.Hoseclamp
ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Monthly
DANGER
Batteryelectrolytecontainssulfuricacid,whichisa deadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwithskin, eyes,orclothing.Wearsafetyglassestoshieldyour eyesandwearrubberglovestoprotectyourhands.
Figure60
RemovingtheBattery
3.Fuelline
WARNING
5.Squeezetheendsofthehoseclampstogetherandslide themawayfromthelter(Figure60).
6.Removethelterfromthefuellines.
7.Installanewlterandmovethehoseclampscloseto thelter(Figure60).
8.Openthefuel-shutoffvalve.
Important:Installthefuellinehosesandsecurewith plastictiesthesameastheywereoriginallyinstalledat thefactorytokeepthefuellineawayfromcomponents thatcancausefuellinedamage.

ServicingtheHigh-Pressure FuelFilter

Donotattempttoservicethehigh-pressurefuellter.The high-pressurelterisintegratedwithinthefuel-pumpmodule. Thefuellterandothercomponentsinsidethefuel-pump modulearenotserviceable.
Important:Donotattempttoopenthefuel-pump module.
EnsurethatanAuthorizedServiceDealerreplacesthe fuel-pumpmodulewiththehigh-pressurefuellter.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltank.
Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponents,causingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.
•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
WARNING
Incorrectbatterycableroutingcoulddamagethe machineandcables,causingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.
•Alwaysdisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.
•Alwaysconnectthepositive(red)batterycable beforeconnectingthenegative(black)cable.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Disconnectthenegativebatterycable(black)fromthe negative(-)batteryterminal(Figure61).
4.Slidetheredterminalbootoffthepositive(+)battery terminalandremovethepositive(red)batterycable (Figure61).
43
Page 44
5.Removethewingnutsecuringthebatteryclamp
G008804
(Figure61).
ChargingtheBattery
6.Removetheclamp(Figure61).
7.Removethebattery(Figure61).
WARNING
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportantto preventbatterydamagewhenthetemperatureisbelow 0°C(32°F).
1.Chargebatteryfor10to15minutesat25to30Aor for30minutesat10A.
2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthecharger leadsfromthebatteryposts(Figure62).
3.Installthebatteryinthemachineandconnectthe batterycables;refertoInstallingtheBattery(page44).
Note:Donotrunthemachinewiththebattery disconnected;otherwise,electricaldamagemayoccur.
Figure61
InstallingtheBattery
1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure61).
2.Installthepositive(red)batterycabletothepositive (+)batteryterminal.
3.Installthenegative(black)batterycableandground wiretothenegative(-)batteryterminal.
4.Securethecableswith2bolts,2washers,and2locknuts (Figure61).
5.Slidetheredterminalbootontothepositive(+)battery terminal.
6.Installtheclampandsecureitwiththewingnut(Figure
61).
1.Positivebatterypost
2.Negativebatterypost
Figure62
3.Red(+)chargerlead
4.Black(-)chargerlead
44
Page 45

ServicingtheFuses

g020464
Theelectricalsystemisprotectedbyfuses.Itrequiresno maintenance,however,ifafuseblowscheckthecomponent andcircuitforamalfunctionorshort.
1.Thefusesarelocatedonrightconsolenexttotheseat (Figure63).
2.Toreplacethefuses,pulloutthefusetoremoveit.
3.Installanewfuse(Figure63).
2.Makesurethattheboosterbatteryisagoodandfully chargedlead-acidbatteryat12.6Vorgreater.
Note:Useproperlysizedjumpercableswithshort lengthstoreducevoltagedropbetweensystems.Make surethatthecablesarecolorcodedorlabeledforthe correctpolarity.
CAUTION
Connectingthejumpercablesincorrectly (wrongpolarity)canimmediatelydamagethe EFIsystem.
Becertainofbatteryterminalpolarityand jumpercablepolaritywhenconnectingthe batteries.
WARNING
Batteriescontainacidandproduceexplosive gases.
•Shieldtheeyesandfacefromthebatteries atalltimes.
Figure63
1.Optionalaccessory(15A)4.Main(25A)
2.Charge(25A)5.Console
3.PTO(10A)

Jump-StartingtheMachine

1.Checkandcleancorrosionfromthebatteryterminals beforejump-starting.Ensurethattheconnectionsare tight.
CAUTION
Corrosionorlooseconnectionscancause unwantedelectricalvoltagespikesatanytime duringthejump-startingprocedure.
Donotattempttojump-startthemachine withlooseorcorrodedbatteryterminals,or damagetotheengineorEFImayoccur.
•Donotleanoverthebatteries.
Note:Besurethattheventcapsaretightandlevel. Placeadampcloth,ifavailable,overanyventcaps onbothbatteries.Besurethatthevehiclesdonot touchandthatbothelectricalsystemsareoffandatthe sameratedsystemvoltage.Theseinstructionsarefor negativegroundsystemsonly.
3.Connectthepositive(+)cabletothepositive(+) terminalofthedischargedbatterythatiswiredtothe starterorsolenoidasshowninFigure64.
Figure64
DANGER
Jump-startingaweakbatterythatiscracked, frozen,orhasalowelectrolyteleveloran open/shortedbatterycellcancausean explosion,resultinginseriouspersonalinjury.
Donotjump-startaweakbatteryifthese conditionsexist.
1.Positive(+)cableon dischargedbattery
2.Positive(+)cableon boosterbattery
3.Negative(–)cableonthe boosterbattery
4.Negative(–)cableonthe engineblock
45
5.Boosterbattery
6.Dischargedbattery
7.Engineblock
Page 46
4.Connecttheotherendofthepositivecabletothe
G029644
g0131 17
1
2
positiveterminaloftheboosterbattery.
DriveSystem
5.Connecttheblacknegative(–)cabletotheother terminal(negative)oftheboosterbattery.
6.Makethenalconnectionontheengineblockofthe stalledvehicle(nottothenegativebatterypost)away fromthebatteryandstandback(Figure65).
Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily
Inspecttheseatbeltforwear,cuts,andproperoperationof theretractorandbuckle.Replacetheseatbeltifitisdamaged.

Checkingthe Rollover-Protection-System (ROPS)Knobs

ServiceInterval:Beforeeachuseordaily
WARNING
Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraisedlockedpositionandusethe seatbelt.
Ensurethattheseatissecuredtothemachine.
Figure65
1.Engineblock
7.Startthevehicleandremovethecablesinthereverse orderofconnection..
Note:Disconnecttheengineblock(black)rst.
2.Negative(–)cable
Checkthatboththemountinghardwareandtheknobsarein goodworkingcondition.Makesurethattheknobsarefully engagedwiththeROPSintheraisedposition.Theupper hoopoftherollbarmayneedtobepushedforwardorpulled rearwardtofullyengagebothknobs(Figure66).
46
Page 47

AdjustingtheTracking

g029647
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2
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1.Disengagetheblade-controlswitch(PTO).
2.Drivetoanopen,atareaandmovethemotion-control leverstotheNEUTRAL-LOCKposition.
3.MovethethrottlemidwaybetweentheFASTandSLOW positions.
4.Movebothmotion-controlleversforwarduntilthey bothhitthestopsintheT-slot.
5.Checkwhichwaythemachinetracks.
6.Ifthemachinetrackstotheright,loosentheboltsand adjusttheleftstopplaterearwardontheleftT-slot untilthemachinetracksstraight(Figure67).
7.Ifthemachinetrackstotheleft,loosentheboltsand adjusttherightstopplaterearwardontherightT-slot untilthemachinetracksstraight(Figure67).
8.Tightenthestopplate(Figure67).
1.ROPSknob(locked position)
2.PulltheROPSknobout, androtateit90degrees tochangetherollbar position.
Figure66
3.Rollbarintheupright position
4.Rollbarinthefolded position
Figure67
Leftcontrollevershown
1.Controllever3.Stopplate
2.Bolt
47
Page 48

CheckingtheTirePressure

g029648
1
CheckingtheWheelHub
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat90kPa(13psi). Uneventirepressurecancauseunevencut.Checkthetires whentheyarecold,togetthemostaccuratepressurereading.
Note:Thefronttiresaresemi-pneumatictiresanddonot requireair-pressuremaintenance.
Figure68
SlottedNut
ServiceInterval:Aftertherst100hours
Every500hours
Checkandensurethatthetorqueoftheslottednutis286to 352N∙m(211to260ft-lb).
Note:Donotuseanti-seizecompoundonthewheelhub.

CheckingtheWheelLugNuts

Checkandtorquethewheellugnutsto122to129N∙m(90 to95ft-lb).
Figure69
1.Slottednut
48
Page 49
AdjustingtheCaster-Pivot

UsingtheClutchShim

Bearing
ServiceInterval:Every500hours/Yearly(whichevercomes
rst)
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethedustcapfromcasterandtightenthe locknut(Figure70).
4.Tightenthelocknutuntilthespringwashersareat, andthenbackoffa1/4turntoproperlysetthepreload onthebearings(Figure70).
Important:Makesurethatthespringwashersare installedcorrectlyasshowninFigure70.
5.Installthedustcap(Figure70).
Somelatermodelyearunitshavebeenbuiltwithclutchesthat containabrakeshim.Whentheclutchbrakehasworntothe pointwheretheclutchnolongerengagesconsistently,you canremovetheshimtoextendtheclutchlife.
Figure71
1.Armature5.Brakespacer
2.Fieldshell6.Regapshim
3.Rotor7.Brakepole
4.Brake-mountingbolt
1.Springwashers
2.Locknut
RemovingtheClutchShim
1.Shutofftheengine,waitforallmovingpartstostop, andremovethekey.
2.Engagetheparkingbrakeandwaitformachinetocool completely.
3.Usinganaircompressor,blowoutanydebrisunderthe brakepoleandaroundthebrakespacers.
Figure70
3.Dustcap
Figure72
4.Checktheconditionofthewire-harnessleads, connectors,andterminals.Cleanorrepairthemas necessary.
49
Page 50
5.Verifythat12Vispresentattheclutchconnector whentheyouengagetheblade-controlswitch(PTO).
6.Measurethegapbetweentherotorandarmature.If thegapisgreaterthan1mm(0.04inch),proceedwith thefollowingsteps:
A.Loosenbothbrakemountingbolts1/2to1full
turnasshowninFigure73.
Note:Donotremovethebrakepolefromthe eldshell/armature.Thebrakepolehasworn tomatchthearmatureandneedstocontinueto matchafteryouremovetheshimtoensurethe properbraketorque.
E.Usinga0.010inchthick-feelergauge,verifythat
agapispresentbetweentherotorandarmature faceonbothsidesofthebrakepoleasshownin
Figure75andFigure76.
Note:Duetothewaytherotorandarmature faceswear(peaksandvalleys),itissometimes difculttomeasurethetruegap.
Figure75
1.Feelergauge
Figure73
1.Brake-mountingbolt
B.Usingneedle-nosepliers,orbyhand,removethe
shim.
Note:Donotdiscardtheshimuntilyouconrm thattheclutchfunctionsproperly.
Figure74
1.Shim
C.Usingapneumaticline,blowoutanydebrisunder
thebrakepoleandaroundthebrakespacers.
Figure76
1.Feelergauge
•Ifthegapislessthan0.010inch,theninstall
theshimandrefertoTroubleshooting(page
69).
•Ifthegapissufcient,proceedtothesafety
checkinstepF.
D.Torqueeachbolt(M6x1)to12.3to13.7N∙m
(9.5to10.5ft-lb).
50
Page 51
F.Performthefollowingsafetycheck:
G029644
i.Sitontheseatandstarttheengine.
ii.Makesurethatthebladesdonotengage
whentheblade-controlswitch(PTO) isintheOFFpositionandtheclutchis disengaged.
Note:Iftheclutchdoesnot disengage,installtheshim,andreferto
Troubleshooting(page69).
iii.Engageanddisengagetheblade-control
switch(PTO)10consecutivetimesto ensurethattheclutchisfunctioning properly.
Note:Iftheclutchdoesnotengage properly,refertoTroubleshooting(page
69).
CoolingSystem Maintenance

CleaningtheEngineScreen andEngine-OilCooler

ServiceInterval:Beforeeachuseordaily
Removeanybuildupofgrass,dirt,orotherdebrisfrom theoilcooler(Figure77).Thishelpsensureadequate cooling,correctenginespeed,andreducesthepossibilityof overheatingandmechanicaldamagetotheengine.
Figure77
51
Page 52
CleaningtheEngineCooling
g029645

CleaningtheHydraulicUnits

FinsandShrouds
ServiceInterval:Every100hours/Yearly(whichevercomes
rst)
1.Disengagetheblade-controlswitch(PTO)andsetthe parkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removetheairintakescreen,recoilstarter,andfan housing(Figure78).
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installtheair-intakescreen,recoilstarter,andfan housing(Figure78).
ServiceInterval:Beforeeachuseordaily
1.Disengagetheblade-controlswitch(PTO)andsetthe parkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Movetheseatforward.
4.Cleanthedebrisandgrassfromthehydraulicunits (Figure79).
5.Positiontheseat.
Figure78
1.Engineguard4.Fanhousing
2.Engineair-intakescreen
3.Bolt
Figure79
1.Hydraulicunits
5.Screw
52
Page 53
BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours
Every500hoursthereafter
1.Drivethemachineontoalevelsurface.
2.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andengagetheparkingbrake.
3.Shutofftheengine,waitforallmovingpartstostop, andremovethekey.
4.Raisethebackofthemachineandsupportthemachine withjackstands.
9.Disengagetheparkingbrake.
10.Turnthewheelhubbyhandinbothdirectionsrelative tothecaliper.
Note:Thewheelhubshouldmovefreelybetween thecaliper.
11.Ifagapisneededorthewheelhubdoesnotmove freely:
A.Disengagetheparkingbrake.
B.Disconnectandne-tunetherearlinkage
assembly:
•Shortenthelinktocreateagap.
•Lengthenthelinktoallowwheelhub
movement.
C.Connecttherear-linkageassembly .
DANGER
Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury.
•Useajackstandwhensupportingthe machine.
•Donotusehydraulicjacks.
5.Removethereartiresfromthemachine.
6.Removeanydebrisfromthebrakearea.
7.Rotatethedrive-wheelreleasehandletothereleased position.RefertoUsingtheDrive-WheelRelease
Valves(page29).
8.CheckifthereisavisiblegapbetweentheL-bracket andthelinkagestop(Figure80).
12.Engagetheparkingbrakeandcheckthegap.
13.Repeatsteps9through13untilyouachieveavisible gapandthewheelhubrotatesfreely.
14.Repeatthisprocedureforthebrakeontheopposite side.
15.Rotatethedrive-wheelreleasehandletotheoperating position;refertoUsingtheDrive-WheelReleaseValves
(page29).
16.Installthereartiresandtorquethelugnuts;referto
CheckingtheWheelLugNuts(page48).
17.Removethejackstands.
Figure80
LeftSideShown
1.L-bracket4.Rear-linkageassembly
2.Linkagestop
3.Gap
5.Caliper
6.Wheelhub
53
Page 54
BeltMaintenance
g017627

InspectingtheBelts

ServiceInterval:Every50hours
Replacethebeltifitisworn.Thesignsofawornbeltinclude squealingwhilethebeltisrotating;thebladesslippingwhile cuttinggrass;andfrayededges,burnmarks,andcrackson thebelt.

ReplacingtheMowerBelt

1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Lowerthemowertothe76mm(3inch)height-of-cut.
4.Removethebeltcovers(Figure81).
Figure81
5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(Figure82).
6.Removethebeltfromthemower-deckpulleys.
7.Removethebeltguideonthespring-loadedidlerarm (Figure82).
8.Removetheexistingbelt.
9.Installthenewbeltaroundthemowerpulleysandthe clutchpulleyundertheengine(Figure82).
Figure82
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
10.Installthebeltguideontheidlerarm(Figure82).
11.Usingtheratchetinthesquarehole,installtheidler spring(Figure82).
Note:Makesuretoseatthespringendsintheanchor grooves.
12.Installthebeltcovers(Figure83).
armfortheratchet
6.Idler-greasetting
7.Beltguide
54
Page 55
Figure83
Figure84

ReplacingtheHydraulic-Pump DriveBelt

1.Disengagetheblade-controlswitch(PTO)andsetthe parkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removemowerbelt;refertoReplacingtheMower
Belt(page54).
4.Raisethemachineandsupportitwithjackstands (Figure84).
1.Idlerpulley
2.Clutchpulley6.Squareholeinidlerarm
3.Pump-drivebelt7.Idlerspring
4.Righthydraulic-pump pulley
5.Lefthydraulic-pumppulley
5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure84).
6.Unhooktheidlerspringfromtheframe(Figure84).
7.Removethebeltfromthehydraulic-unit-drivepulleys andtheenginepulley.
8.Installthenewbeltaroundenginepulleyandthe2 drivepulleys.
9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(Figure84).
10.Installthemowerbelt;refertoReplacingtheMower
Belt(page54).
55
Page 56
ControlsSystem Maintenance

AdjustingtheControl-Handle Position

Thereare2heightpositionsforthecontrollevers—highand low .Removetheboltstoadjusttheheight.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosentheboltsandangenutsinstalledinthelevers (Figure85).
4.Aligntheleversinthefront-to-rearpositionbybringing theleverstogethertotheNEUTRALposition,slidethem untiltheyarealigned,andtightenthebolts(Figure85).
Figure85
1.Bolt
2.Handle4.Nut
3.Controllever
Figure86
5.Iftheendsofthelevershitagainsteachother,refer toAdjustingtheMotion-ControlNeutral-LockPivot
(page58).

AdjustingtheMotion-Control Linkage

Thepump-controllinkagesarelocatedoneithersideofthe fueltank,belowtheseat.Rotatethepumplinkagewitha1/2 inchwrenchforne-tuningadjustmentssothatthemachine doesnotmoveinneutral.Makeanyadjustmentsforneutral positioningonly.
WARNING
Theenginemustberunningandthedrivewheels mustbeturning,sothemotion-controladjustment canbeperformed.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury.
Keepyourngers,hands,andclothingclearof rotatingcomponentsandhotsurfaces.
1.Priortostartingtheengine,pushthedeck-liftpedal, removetheheight-of-cutpin,andlowerthedeckto theground.
2.Raisetherearofmachineandsupportitwithjack stands(orequivalentsupport)justhighenoughto allowthedrivewheelstoturnfreely .
3.Removetheelectricalconnectionfromtheseatsafety switch,locatedunderthebottomcushionoftheseat.
Note:Theswitchisapartoftheseatassembly.
4.Temporarilyinstallajumperwireacrosstheterminals intheconnectorofthemainwiringharness.
56
Page 57
5.Starttheengine.
g027342
Note:Engagetheparkingbrakeandmovethe motion-controlleversoutbeforestartingtheengine. Youdonotneedtobeintheseatbecauseofthe jumperwirebeingused.Runtheengineatfullthrottle andreleasethebrake.
6.Runthemachineatleast5minuteswiththe motion-controlleversatfullforwardspeedtobringthe hydraulicuiduptooperatingtemperature.
7.Bringthemotion-controlleversintotheNEUTRAL position.
8.Adjustthepump-controlrodlengthsbyrotatingthe doublenutsontherodintheappropriatedirection untilthewheelsslightlycreepinreverse(Figure87).

AdjustingtheMotion-Control Damper

Youcanadjustthetopdampermountingbolttoobtaina moredesiredmotion-controlleverresistance.SeeFigure88 formountingoptions.
Figure88
Rightmotion-controllevershown
Figure87
1.Doublenuts
9.Movethemotion-controlleverstotheREVERSE position,andwhileapplyingslightpressuretothelever, allowthereverseindicatorspringstobringthelevers backtoneutral.
Note:Thewheelsmuststopturningorslightlycreep inreverse.
1.T orquethelocknutto23N∙m(17ft-lb).Theboltmust protrudepasttheendofthelocknutaftertorquing.
2.Mostresistance(rmestfeel)
3.Damper
4.Mediumresistance(mediumfeel)
5.Leastresistance(softestfeel)
10.Shutoffthemachine.
11.Removethejumperwirefromwireharnessandplug theconnectorintotheseatswitch.
12.Removethejackstands.
13.Raisethedeckandinstalltheheight-of-cutpin.
14.Checkthatthemachinedoesnotcreepinneutralwhen youdisengagetheparkingbrakes.
57
Page 58

AdjustingtheMotion-Control Neutral-LockPivot

Youcanadjusttheangednuttoobtainthedesired motion-controlleverresistancewhenyoumovethemto theNEUTRAL-LOCKposition.SeeFigure89foradjustment options.
1.Loosenthejamnut.
2.Tightenorloosentheangednuttothedesiredfeel.
HydraulicSystem Maintenance

ServicingtheHydraulic System

HydraulicFluidType:Toro uidorMobil
®
115W -50.
®
HYPR-OIL
™
500hydraulic
Note:Formoreresistance,tightentheangednut.
Note:Forlessresistance,loosentheangednut
3.Tightenthejamnut.
Figure89
1.Flangednut2.Jamnut
Important:Usetheuidspecied.Otheruidscould damagethehydraulicsystem.
EachHydraulicSystemFluidCapacity:1.5L(52oz)per
sidewithlterchange
CheckingtheHydraulicFluid
ServiceInterval:Every50hours—Checkthehydraulic-uid
level.
1.Positionthemachineonalevelsurface.
2.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
3.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Waitfortheengineandhydraulicsystemtocoolfor 10minutes.
Note:Theuidlevelonthedipstickisincorrectifyou checktheuidwhenthemachineishot.
5.Movetheseatforward.
6.Cleantheareaaroundthedipsticksofthehydraulic systemreservoirs(Figure90).
7.Remove1dipstickfromthehydraulicreservoir(Figure
90).
8.Wipethedipstickoffandthreadthedipstickintothe reservoir.
9.Removethedipstickandlookattheend(Figure90).
Note:Iftheuidlevelisattheaddmark,slowlypour onlyenoughuidintothehydraulicreservoirtoraise theleveltothefullorHline.
Important:Donotoverllthehydraulicunits withuid,asdamagemayoccur.Donotrunthe machinewiththeuidbelowtheaddmark.
10.Installthedipstick.
11.Repeatprocedurefortheoppositedipstick.
58
Page 59
G015459
H
3
4
ReplacingtheHydraulicFiltersand HydraulicFluid
ServiceInterval:Aftertherst250hours—Changethe
hydraulicltersandhydraulicuid.
Figure90
Eitherdipstickisusedinthemachine
1.Full3.H—meanshighlevel
2.Add4.Dipsticklocationsunder seat
Every250hours—Changethehydraulicltersand hydraulicuidwhenusingMobil indirtyordustyconditions).
Every500hours—Changethehydraulicltersand hydraulicuidwhenusingToro 500hydraulicuid(moreoftenindirtyordusty conditions).
Toreplacethehydraulicuid,youneedtoremovethe lters.Replacebothatthesametime;refertoServicingthe
HydraulicSystem(page58)fortheoilspecications.
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethemachineandsupportitwithjackstands (Figure91).
®
1uid(moreoften
®
HYPR-OIL
™
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskin, itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistype ofinjury.Gangrenemayresultifthisis notdone.
•Keepyourbodyandhandsawayfrom pinholeleaksornozzlesthateject high-pressurehydraulicuid.
•Usecardboardorpapertondhydraulic leaks.
•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
•Makesurethatallhydraulic-uidhoses andlinesareingoodconditionandthatall hydraulicconnectionsandttingsaretight beforeapplyingpressuretothehydraulic system.
Figure91
1.Jackstands
4.Removeboththemowerbeltandthepump-drive belt;refertoReplacingtheMowerBelt(page54)and
ReplacingtheHydraulic-PumpDriveBelt(page55).
Note:Thispreventsoilfromgettingonthebelts.
5.Placeadrainpanunderthelter,removetheoldlter, andwipethesurfaceclean(Figure92).
59
Page 60
G008968
1
2

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine
Note:Ensurethatthemowerdeckislevelbeforematching
theheightofcut(HOC).
1.Positionthemoweronaatsurface.
2.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
3.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Checkthepressureofthedrivetires.
Figure92
Bottomviewofthemachine
1.Filterlocations
2.Hydrauliclter
Note:Properinationpressureforthetiresis90kPa (13psi).
5.Positionthemowerdecktothe76mm(3inch) height-of-cutposition.
6.Applyathincoatofhydraulicuidtotherubbergasket onthereplacementlter(Figure92).
7.Installthereplacementhydrauliclter.
8.Installthepump-drivebeltandthemowerbelt.
9.Removethejackstandsandlowerthemachine(Figure
91).
10.Adduidtothehydraulicreservoirandcheckforany leaks.
11.Cleanupanyspilleduid.
12.Starttheengineandletitrunforabout2minutesto purgeairfromthesystem.
13.Shutofftheengineandcheckforleaks.
14.Checktheuidlevelwhiletheoiliscold.
15.Ifrequired,adduidtothehydraulicreservoir.
Note:Donotoverll.
LevelingtheDeck
1.Positionthemoweronaatsurface.
2.Shutofftheengine,waitforallmovingpartstostop, removethekey,andengagetheparkingbrake.
3.Checkthepressureinthedrivetires.
Note:Properinationpressureforthetiresis90kPa (13psi).
4.Positionthetransportlockinthelatchingposition.
5.Pushthedeckliftpedalallthewayforwardandthe deckwilllatchatthe14cm(5-1/2inch)transport position(Figure93).
Figure93
1.Deck-liftpedal
2.Height-of-cutpin
3.Transportlock
60
Page 61
6.Inserttheheight-adjustmentpinintothe7.6cm(3
g029650
1
2
3 4
12
g029651
1
inch)height-of-cutlocation.
7.Releasethetransportlockandallowthedecktolower tothecuttingheight.
8.Raisethedischargechute.
9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA)as showninFigure94.
Note:Themeasurementshouldread7.6mm(3 inches)
Figure95
1.Flangedlocknut3.Jamnut
2.Adjusterscrew4.Y oke
12.Ifthefrontdecklinksdonothaveenoughadjustment toachieveaccuratecutheight,loosenthe2boltsat thebottomoftheheight-of-cutplatetoadjustthe single-pointsystem(Figure96).
Figure94
1.7.6cm(3inches)at positionAiscorrect.
2.8.3cm(3-1/4inches)at positionBiscorrect.
3.Measureherefromthe bladetiptothehard surface.
4.MeasureatpositionAand Bonbothsides.
10.Ifneeded,loosentheangedlocknutonthesideofthe yokeandthejamnutontop.
11.Fine-tunetheadjusterscrewbyturningittoget7.6 mm(3inch)height(Figure95).
Note:Toincreasetheheight,turntheadjuster screwclockwise;todecreasetheheight,turnit
1.Boltsatthebottomoftheheight-of-cutplate
Figure96
counterclockwise.
13.Ifthedeckistoolow ,tightenthesingle-point adjustmentboltbyrotatingitclockwise.Ifthedeckis toohigh,loosenthesingle-pointadjustmentboltby rotatingitcounterclockwise(Figure97).
Note:Loosenortightenthesingle-pointadjustment boltenoughtomovetheheight-of-cutplatemounting boltsatleast1/3thelengthoftheavailabletravelin theirslots.Thisregainssomeup-and-downadjustment oneachofthe4decklinks.
61
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g017036

ServicingtheCuttingBlades

Toensureasuperiorqualityofcut,keepthebladessharp.For convenientsharpeningandreplacement,keepextrablades onhand.
WARNING
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownatyouorbystanders, resultinginseriouspersonalinjuryordeath.
•Inspectthebladesperiodicallyforwearor damage.
Figure97
1.Single-pointadjustmentbolt
14.Tightenthe2boltsatthebottomoftheheight-of-cut plate(Figure96).
Note:Formostconditions,adjustthebackbladetip4 mm(1/4inch)higherthanthefront.
15.Torquethe2boltsto37to45N∙m(27to33ft-lb).
16.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(positionB)as showninFigure94.
Note:Themeasurementshouldread8.3cm(3-1/4 inches)
17.Fine-tunetheadjusterscrewbyturningittoget8.3 mm(3-1/4inches)height(Figure95).
Note:Toincreasetheheight,turntheadjustment nutclockwise;todecreasetheheight,turnit counterclockwise.
18.Measureuntilall4sidesarethecorrectheight.
•Replaceawornordamagedblade.
BeforeInspectingorServicingthe Blades
1.Parkthemachineonalevelsurface,Disengagethe blade-controlswitch(PTO),andsettheparkingbrake.
2.Turntheignitionkeytooff.Removethekey,and disconnectthesparkplugwiresfromthesparkplugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure98).
2.Iftheedgesarenotsharporhavenicks,removeand sharpentheblade;refertoRemovingtheBlades(page
63)andSharpeningtheBlades(page64).
3.Inspecttheblades,especiallyinthecurvedarea.
4.Ifyounoticeanycracks,wear,oraslotforminginthis area,immediatelyinstallanewblade(Figure98).
19.Tightenallthenutsonthedeck-lift-armassemblies.
20.Lowerthedischargechute.
Figure98
1.Cuttingedge3.Wear/slotforming
2.Curvedarea4.Crack
62
Page 63
CheckingforBentBlades
RemovingtheBlades
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure99).
4.Measurefromalevelsurfacetothecuttingedge, positionA,oftheblades(Figure99).
Replaceabladeifithitsanobject,ifthebladeisoutofbalance, orifthebladeisbent.Toensureoptimumperformanceand continuedsafetyconformanceofthemachine,usegenuine Tororeplacementblades.Replacementbladesmadebyother manufacturersmayresultinnonconformancewithsafety standards.
1.Holdthebladeendusingaragorathicklypadded glove.
2.Removethebladebolt,curvedwasher,andbladefrom thespindleshaft(Figure100).
Figure99
1.Measureherefromblade tohardsurface
5.Rotatetheoppositeendsofthebladesforward.
6.Measurefromalevelsurfacetothecuttingedgeofthe bladesatthesamepositionasinstep4.
Note:Thedifferencebetweenthedimensions obtainedinsteps4and5mustnotexceed3mm (1/8inch).
Note:Ifthisdimensionexceeds3mm(1/8inch),the bladeisbentandmustbereplaced.
2.PositionA
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedblade withanewblade.
•Donotleorcreatesharpnotchesinthe edgesorsurfacesoftheblade.
Figure100
1.Sailareaoftheblade3.Curvedwasher
2.Blade4.Bladebolt
63
Page 64
SharpeningtheBlades
InstallingtheBlades
1.Usealetosharpenthecuttingedgeatbothendsof theblade(Figure101).
Note:Maintaintheoriginalangle.
Note:Thebladeretainsbalanceifyouremovethe
sameamountofmaterialfrombothcuttingedges.
Figure101
1.Sharpenattheoriginalangle
2.Checkthebalanceofthebladebyputtingitonablade balancer(Figure102).
Note:Ifthebladestaysinahorizontalposition,the bladeisbalancedandreadytouse.
1.Installthebladeontothespindleshaft(Figure103).
Important:Thecurvedpartoftheblademust pointupwardtowardtheinsideofthemowerto ensurepropercutting.
2.Installthespringdiskandbladebolt(Figure103).
Note:Installthespring-diskconetowardthebolt head.
3.Torquethebladeboltto115to150N∙m(85to110 ft-lb).
Figure102
1.Blade2.Balancer
3.Ifthebladeisnotbalanced,lesomemetalofftheend ofthesailareaonly(Figure100).
4.Repeatthisprocedureuntilthebladeisbalanced.
Figure103
1.Sailareaoftheblade3.Springdisk
2.Blade4.Bladebolt
64
Page 65

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,lockoutthe spring-loadeddeckarms.
WARNING
Deck-lift-armassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.
Donotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.
1.Shutofftheengine,waitforallofthemovingpartsto stop,removethekey,andengageparkingbrake.
2.Removetheheight-adjustmentpinandlowerthedeck totheground.
3.Placetheheight-adjustmentpininthe7.6cm(3inch) height-of-cutlocation.
Note:Thislocksthedeck-liftarmsinthelowest positionsothatwhenyouremovethedeck,thestored energyinthedeckspringisreleased.
4.Removethebeltcovers.
5.Lifttheoorpanandinsertaratchetintothesquare holeinthedeckidler(Figure104).
6.Rotatethedeckidlerclockwiseandremovethemower belt(Figure104).
Figure104
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
armfortheratchet
6.Idlergreasetting
7.Beltguide
7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure105.
65
Page 66
Figure105
g015594
1
6 2
4
7
3
5
1.Rightstabilizer
2.Deckstrut(rightsideshown)
3.Removetheshoulderboltandnut.
4.Removetheshoulderboltandnut.
ReplacingtheGrassDeector
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsatyouorbystanders, resultinginseriousinjury.Also,contactwiththe bladecouldoccur.
Donotoperatethelawnmowerunlessyouinstalla coverplate,mulchplate,grassdeector,orbagger.
1.Removethelocknut,bolt,spring,andspacerholding thedeectortothepivotbrackets(Figure106).
2.Removethedamagedorworngrassdeector(Figure
106).
8.Raisethedeckstrutsandsecurethemintheup position.
9.Slidethedeckouttotherightsideofthemachine.
Figure106
1.Bolt
2.Spacer6.Grassdeector
3.Locknut
4.Spring
5.Springinstalled
7.J-hookendofspring
3.Placethespacerandthespringontograssdeector.
4.Place1J-hookendofthespringbehindthedeckedge.
Note:Makesurethat1J-hookendofthespringis installedbehindthedeckedgebeforeinstallingthebolt asshowninFigure106.
5.Installtheboltandthenut.
6.Place1J-hookendofthespringaroundthegrass deector(Figure106).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefully downposition.
66
Page 67
Cleaning
g030538
Storage

CleaningundertheMower

ServiceInterval:Beforeeachuseordaily
1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheNEUTRAL-LOCKposition, andsettheparkingbrake.
2.Shutofftheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.RaisethemowertotheTRANSPORTposition.

CleaningtheSuspension System

Note:Donotcleantheshockassemblieswithpressurized
water(Figure107).
Figure107

DisposingofWaste

Engineoil,batteries,hydraulicuid,andenginecoolantare pollutantstotheenvironment.Disposeoftheseaccordingto yourstateandlocalregulations.

CleaningandStorage

1.Disengagetheblade-controlswitch(PTO),setthe parkingbrake,andturntheignitionkeytoOff. Removethekey.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engineandhydraulicsystem.Cleandirtandchafffrom theoutsideoftheengine-cylinder-headnsandblower housing.
Important:Youcanwashthemachinewithmild detergentandwater.Donotpressure-washthe machine.Avoidexcessiveuseofwater,especially nearthecontrolpanel,engine,hydraulicpumps, andmotors.
3.Checkthebrake.
4.Servicetheaircleaner;refertoServicingtheAir
Cleaner(page37).
5.Greasethemachine;refertoLubrication(page34).
6.Changethecrankcaseoil;refertoChangingtheEngine
Oil(page39).
7.Checkthetirepressure;refertoCheckingtheTire
Pressure(page48).
8.Changethehydrauliclters;refertoReplacingthe
HydraulicFiltersandHydraulicFluid(page59).
9.Chargethebattery;refertoChargingtheBattery(page
44).
10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.
Note:Runthemachinewiththeblade-controlswitch (PTO)engaged,andtheengineathighidlefor2to 5minutesafterwashing.
11.Checktheconditionoftheblades;refertoServicing
theCuttingBlades(page62).
12.Preparethemachineforstoragewhennon-useoccurs over30days.Preparethemachineforstorageas follows:
A.Addapetroleum-basedstabilizer/conditionerto
fuelinthetank.Followmixinginstructionsfrom thestabilizermanufacturer.Donotuseanalcohol basedstabilizer(ethanolormethanol).
Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandusedat alltimes.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
C.Shutofftheengine,allowittocool,anddrainthe
fueltank;refertoServicingtheFuelTank(page
43).
67
Page 68
D.Restarttheengineandrunituntilitstops.
E.Disposeoffuelproperly .Recycleasperlocal
codes.
Important:Donotstore stabilizer/conditionedfuelover90days.
13.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamaged.
14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
15.Storethemachineinaclean,drygarageorstoragearea.
16.Removethekeyfromtheignitionswitchandkeepit outofreachofchildrenorotherunauthorizedusers.
17.Coverthemachinetoprotectitandkeepitclean.
68
Page 69
Troubleshooting
Problem
Themalfunctionindicatorlight(MIL) comeson.
Thestarterdoesnotcrank.
PossibleCauseCorrectiveAction
1.Theengineistoohot.
2.Thereisoldgasinthegastank.2.Usenewgas.
3.Thefuel-shutoffvalveisnotopen 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.Theparkingbrakeisnotengaged.
3.Themotion-controlleversarenotin theNEUTRAL-LOCKposition.
4.Theoperatorisnotseated.
5.Thebatteryisdead.
6.Theelectricalconnectionsare corrodedorloose.
7.Thefuseisblown.7.Replacethefuse.
8.Therelayorswitchiswornor damaged.
1.Turntheengineoffandletitcool.
3.Openthefuel-shutoffvalve.
precleanerareclean.Replaceif necessary.
5.Chargeorreplacethebattery.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
8.Ensureagood12–voltbatteryisbeing 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,orstalefuelinthe fuelsystem.
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.
69
Page 70
Problem
PossibleCauseCorrectiveAction
Theenginelosespower.
Theengineoverheats.
Themowerpullsleftorright(withlevers fullyforward).
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,orstalefuelinthe fuelsystem.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.
3.Thecoolingnsandtheairpassages abovetheengineareplugged.
1.Thetrackingneedsadjustment1.Adjustthetracking.
2.Thetirepressureisnotcorrectinthe drivetires.
1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.
2.Thepumpbeltisworn,looseorbroken.
3.Thepumpbeltisoffapulley .3.Changethebelt.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
5.Thehydraulic-uidlevelislowortoo hot.
2.Cleantheair-cleanerelement.
4.Removetheobstructionfromthe coolingnsandtheairpassages.
7.ContactanAuthorizedServiceDealer.
3.Removetheobstructionfromthe coolingnsandtheairpassages.
2.Adjustthetirepressureinthedrive tires.
2.Changethebelt.
5.Addhydraulicuidtoreservoirsorletit cooldown.
Thereisabnormalvibration.
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.Themowerdeckbeltisoffthepulley.
3.Thepumpdrivebeltisworn,loose,or 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.
70
Page 71
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.
71
Page 72
Schematics
G0131 19
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)
72
Page 73
Notes:
73
Page 74
Notes:
74
Page 75
Notes:
75
Page 76
TheToroWarranty
ALimitedWarranty(seewarrantyperiodsbelow)Contractor
Landscape
Equipment (LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,T oroWarrantyCompany ,pursuanttoanagreement betweenthem,jointlypromisetotheoriginalpurchasertorepairtheT oroProducts listedbelowifdefectiveinmaterialsorworkmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchase:
ProductsWarrantyPeriod
21in.Mowers2yearsResidentialUse
1yearCommercialUse
3
•Engines
Honda–2years
Kawasaki–3years
30in.Mowers2yearsResidentialUse
1yearCommercialUse
3
•Engines
Mid-SizeWalk-BehindMowers
3
•Engines
GrandStand
3
•Engines
®
ZMaster
•Engines
ZMaster
•Engines ZMaster
•Engines
3
®
3
®
3
2000SeriesMowers
3000SeriesMowers
5000SeriesMowers
®
Mowers
Kawasaki–3years
2years
Kawasaki–3years
5yearsor1,200hours
3years
4yearsor500hours
3years
5yearsor1,200hours 3years 5yearsor1,200hours
KohlerCommand–2years
KohlerEFI–3years
®
ZMaster
•Engines
ZMaster
•Engines
ZMaster
•Engines
3
®
7000SeriesMowers
3
®
8000SeriesMowers
3
6000SeriesMowers
5yearsor1,200hours
Kawasaki–3years
5yearsor1,200hours
2years
2yearsor1,200hours
2years
AllMowers
•Battery90daysPartsandLabor
1yearPartsonly
•BeltsandTires90days
•Attachments1year
1
Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone
locationisconsideredcommercialuseandthecommercialwarrantywouldapply .
2
Whicheveroccursrst.
3
SomeenginesusedonT oroProductsarewarrantedbytheenginemanufacturer .
1
1
2
2
2
2
2
2
2
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,accessourwebsiteat www.T oro.com.Youmayalsocallthenumberslistedinitem#3tousethe 24-hourT oroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)totheService Dealer.Thedealerwilldiagnosetheproblemanddetermineifitiscovered underwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith theassistanceprovided,contactusat:
ToroWarrantyCompany
811 1LyndaleAvenueSouth
Bloomington,MN55420-1 196
888-865-5676(U.S.Customers)
888-865-5691(Canadacustomers)
OwnerResponsibilities
YoumustmaintainyourToroProductbyfollowingthemaintenanceprocedures 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
•Anyproductorpartwhichhasbeenalteredormisusedorneglectedorrequires
replacementorrepairduetoaccidentsorlackofpropermaintenance
•Pickupanddeliverycharges
•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService
Dealer
•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure(consult
Operator'sManualformoredetails)
–Removingcontaminantsfromthefuelsystemisnotcovered
–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmorethan
10%ethanolormorethat15%MTBE
–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone
month
GeneralConditions
AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro ServiceDealerusingT oroapprovedreplacementparts.
NeitherTheToroCompanynorToroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro Productscoveredbythiswarranty,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty .
Allimpliedwarrantiesofmerchantability(thattheproductistforordinaryuse) andtnessforuse(thattheproductistforaparticularpurpose)arelimitedto thedurationoftheexpresswarranty.
Somestatesdonotallowexclusionsofincidentalorconsequentialdamages, orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions andlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirToroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry, province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheT oroimporter.Ifallother remediesfail,youmaycontactusatT oroWarrantyCompany.
AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.
374-0252RevH
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