Toro 79408, 79409 Operator's Manual

FormNo.3360-403RevA

Z300ZMaster

®

witha34in
7-GaugeSideDischargeMower
orwitha40in7-GaugeSide
DischargeMower

ModelNo.79408—SerialNo.280000001andUp

ModelNo.79409—SerialNo.280000001andUp

Registeratwww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Theenclosed

Engine Owner’ s Man ual

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

issupplied

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

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

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

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

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

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

ToroRidingMowerSafety....................................5

SlopeChart..........................................................7

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

ProductOverview......................................................10

©2008—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Controls.............................................................10

Operation...................................................................11

AddingFuel.......................................................11

CheckingtheEngineOilLevel............................12

ThinkSafetyFirst...............................................12

OperatingtheParkingBrake...............................13

StartingandStoppingtheEngine........................14

OperatingthePowerTakeOff(PTO).................15

TheSafetyInterlockSystem................................15

DrivingForwardorBackward.............................16

StoppingtheMachine.........................................17

AdjustingtheHeight-of-Cut...............................17

UsingtheLiftAssistPedal..................................17

AdjustingtheAnti-ScalpRollers.........................18

PositioningtheSeat............................................18

PushingtheMachinebyHand.............................18

UsingtheSideDischarge....................................19

TransportingMachines.......................................19

LoadingMachines..............................................20

OperatingTips...................................................20

Maintenance...............................................................22

RecommendedMaintenanceSchedule(s)................22

Lubrication.............................................................22

GreasingandLubrication...................................22

LubricatingtheCasterWheelHubs.....................24

EngineMaintenance...............................................26

ServicingtheAirCleaner....................................26

ServicingtheEngineOil.....................................27

ServicingtheSparkPlugs....................................28

FuelSystemMaintenance.......................................29

DrainingtheFuelTank.......................................29

ReplacingtheFuelFilter.....................................29

ElectricalSystemMaintenance................................30

ServicingtheBattery...........................................30

ServicingtheFuses.............................................32

DriveSystemMaintenance.....................................33

CheckingtheTirePressure.................................33

AdjustingtheCasterPivotBearing......................33

CoolingSystemMaintenance..................................34

CleaningtheAirIntakeScreen............................34

CleaningtheEngineCoolingSystem...................34

BrakeMaintenance.................................................34

ServicingtheBrakes...........................................34

BeltMaintenance....................................................35

InspectingtheBelts............................................35

ReplacingtheMowerBelt...................................35

CheckingandReplacingthePumpDrive

Belt................................................................35

ControlsSystemMaintenance.................................36

AdjustingtheControlHandleNeutral

Position..........................................................36

AdjustingtheTracking........................................37

HydraulicSystemMaintenance...............................38

ServicingtheHydraulicSystem...........................38

MowerDeckMaintenance......................................40

LevelingtheMower............................................40

ServicingtheCuttingBlades...............................41

ReplacingtheGrassDeector.............................44

Cleaning.................................................................45

CleaningUndertheMower.................................45

WasteDisposal...................................................45

Storage.......................................................................45

Troubleshooting.........................................................47

Schematics.................................................................49

3

Safety

•Useextracarewhenhandlinggasolineandother
fuels.Theyareammableandvaporsareexplosive.

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

Thisproductiscapableofamputatinghandsand
feetandthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass
or,whenequippedwithagrassbagger,forcatching
cutgrass.Anyuseforpurposesotherthanthesecould
provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard
B71.4-2004.

Training

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

•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The
ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor
servicetheequipment.Localregulationsmayrestrict
theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor
accidentsorinjuriesoccurringtohimselforherself,
otherpeopleorproperty.

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling.
Donotsmoke.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes
andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis
engagedbeforestartingengine.Starttheengineonly
fromtheoperator’sposition.Useseatbelts.

•Neverraisemowerwiththebladesrunning.

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

•Neveroperatewiththedischargedeectorraised,
removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor
overspeedtheengine.

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

•Stopequipmentandinspectbladesafterstriking
objectsorifanabnormalvibrationoccurs.Make
necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

Preparation

•Evaluatetheterraintodeterminewhataccessories
andattachmentsareneededtoproperlyand
safelyperformthejob.Onlyuseaccessoriesand
attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety
glassesandhearingprotection.Longhair,loose
clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused
andremoveallobjectssuchasrocks,toysandwire
whichcanbethrownbythemachine.

•Nevercarrypassengersandkeeppetsandbystanders
away.

•Bealert,slowdownandusecautionwhenmaking
turns.Lookbehindandtothesidebeforechanging
directions.

•Slowdownandusecautionwhencrossingroadsand
sidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddo
notpointitatanyone.

•Donotoperatethemowerundertheinuenceof
alcoholordrugs.

4

•Useextremecarewhenloadingorunloadingthe
machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

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

•Donotmowslopeswhengrassiswet.Slippery
conditionsreducetractionandcouldcausesliding
andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

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

•Reducespeedanduseextremecautiononslopes.

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

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

•Avoidsuddenstartswhenmowinguphillbecause
themowermaytipbackwards.

•Beawarethatlossoftractionmayoccurgoing
downhill.Weighttransfertothefrontwheelsmay
causedrivewheelstoslipandcauselossofbraking
andsteering.

•Alwaysavoidsuddenstartingorstoppingona
slope.Iftireslosetraction,disengagethebladesand
proceedslowlyofftheslope.

•Followthemanufacturer’srecommendationsfor
wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother
attachments.Thesecanchangethestabilityofthe
machineandcauselossofcontrol.

Maintenanceandstorage

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

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

•Letenginecoolbeforestoringanddonotstorenear
ame.

•Shutofffuelwhilestoringortransporting.Donot
storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained
personneltoservicemachine.

•Usejackstandstosupportcomponentswhen
required.

•Carefullyreleasepressurefromcomponentswith
storedenergy.

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

•Usecarewhencheckingblades.Wraptheblade(s)or
weargloves,andusecautionwhenservicingthem.
Onlyreplaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.If
possible,donotmakeadjustmentswiththeengine
running.

•Chargebatteriesinanopenwellventilatedarea,
awayfromsparkandames.Unplugchargerbefore
connectingordisconnectingfrombattery.W ear
protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged
decals.

•UseonlyToroapprovedattachments.Warrantymay
bevoidedifusedwithunapprovedattachments.

ToroRidingMowerSafety

•Engineexhaustcontainscarbonmonoxide,whichis
anodorless,deadlypoisonthatcankillyou.Donot
runengineindoorsorinanenclosedarea.

•Stoptheengine,disconnectsparkplugwire(s)and
removekeybeforeperforminganyservice,repairs,
maintenanceoradjustments.

•Keephands,feet,hair,andlooseclothingawayfrom
attachmentdischargearea,undersideofmowerand
anymovingpartswhileengineisrunning.

•Donottouchequipmentorattachmentpartswhich
maybehotfromoperation.Allowtocoolbefore
attemptingtomaintain,adjustorservice.

•Batteryacidispoisonousandcancauseburns.Avoid
contactwithskin,eyes,andclothing.Protectyour
face,eyes,andclothingwhenworkingwithabattery.

•Batterygasescanexplode.Keepcigarettes,sparks
andamesawayfrombattery.

•Ifloadingthemachineontoatrailerortruck,usea
single,full-widthramponly.Therampangleshould
notexceed15degrees.

5

SafeHandlingofGasoline:

Toavoidpersonalinjuryorpropertydamage,useextra
carewhenhandlinggasolineandotherfuels.Theyare
ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipesandother
sourcesofignition.

•Neverremovethegascaporaddfuelwhenthe
engineisrunning.Allowtheenginetocoolbefore
refueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerinside
wherethereisanopename,suchasnearawater
heaterorfurnace.

•Neverllcontainersinsideavehicleoronatruckor
trailerwithaplasticliner.Alwaysplacecontainerson
thegroundawayfromyourvehiclebeforelling.

•Keepthenozzleincontactwiththerimofthefuel
tankorcontaineropeningatalltimesuntilthefueling
iscomplete.Donotuseanozzlelock-opendevice.

•Iffuelisspilledonclothing,changeclothing
immediately.

•Neveroverllthefueltank.Replacegascapand
tightensecurely .

•Keepnutsandboltstight,especiallytheblade
attachmentbolts.Keepequipmentingood
condition.

•Checkforproperbrakeoperationfrequently.Adjust
andserviceasrequired.

6

SlopeChart7SafetyandInstructional
Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

98-5954

1-403005

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

2.Nore,opename,or
smoking.

3.Causticliquid/chemical
burnhazard

4.Weareyeprotection9.Flusheyesimmediately

54-9220

5.ReadtheOperator’s
Manual.

6.Keepbystandersasafe
distancefromthebattery.

7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries

8.Batteryacidcancause
blindnessorsevereburns.

withwaterandgetmedical
helpfast.

10.Containslead;donot
discard.

Manufacturer’sMark

66-1340

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

68-8340

8

109-2356

1.Fast3.Neutral

2.Slow

109-2463

112-3830

112-3831

4.Reverse

112-3832

112-3834

109-2467

109-2490

112-3836

109-2539

9

112-3833

ProductOverview

Figure3

1.Sidedischargechute5.Fuelcap(bothsides)

2.Height-of-cutselectionpin

3.Controls

4.Motioncontrollever8.Frontcasterwheel

6.Parkingbrakelever

7.Mowerdeck

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe
engineandoperatethemachine(Figure3andFigure4).

Figure4

1.Ignitionswitch

2.Hourmeter5.Throttlecontrol

3.PTOSwitch

4.Chokelever

10

UsingtheHourMeter

Thehourmeter(Figure5)recordsthenumberofhours
theenginehasoperated.Itoperateswhentheengine
isrunning.Usethesetimesforschedulingregular
maintenance.

Figure5

1.Hourmeter

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

UseUnleadedRegularGasolinesuitablefor
automotiveuse(85pumpoctaneminimum).Leaded
regulargasolinemaybeusedifunleadedregularisnot
available.

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

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

UsingtheFuelShutoffValve

Themachinehas2fueltanks,oneontheleftsideand
theotherontherightside.Eachtankconnectstoa
checkvalveandthentoatee.Fromthereacommon
fuellineleadstotheengine(Figure6).

Closethefuelshutoffvalvebeforetransportingor
storingthemachine.

•Fillthefueltankoutdoors,inanopenarea,
whentheengineiscold.Wipeupany
gasolinethatspills.

•Neverllthefueltankinsideanenclosed
trailer.

•Donotllthefueltankcompletelyfull.Add
gasolinetothefueltankuntilthelevelis1/4
to1/2inch(6to13mm)belowthebottomof
thellerneck.Thisemptyspaceinthetank
allowsgasolinetoexpand.

•Neversmokewhenhandlinggasoline,and
stayawayfromanopenameorwhere
gasolinefumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand
keepitoutofthereachofchildren.Never
buymorethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaust
systeminplaceandinproperworking
condition.

1.Fuelshutoffvalve

Figure6

11

Important:Donotusefueladditivescontaining
methanolorethanol.

Incertainconditionsduringfueling,static
electricitycanbereleasedcausingaspark
whichcanignitethegasolinevapors.Are
orexplosionfromgasolinecanburnyouand
othersandcandamageproperty.

•Alwaysplacegasolinecontainersonthe
groundawayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsidea
vehicleoronatruckortrailerbedbecause
interiorcarpetsorplastictruckbedliners
mayinsulatethecontainerandslowtheloss
ofanystaticcharge.

•Whenpractical,removegas-powered
equipmentfromthetruckortrailerand
refueltheequipmentwithitswheelsonthe
ground.

•Ifthisisnotpossible,thenrefuelsuch
equipmentonatruckortrailerfroma
portablecontainer,ratherthanfroma
gasolinedispensernozzle.

Addthecorrectamountofgasstabilizer/conditioner
tothegas.

Note:Afuelstabilizer/conditionerismosteffective
whenmixedwithfreshgasoline.Tominimizethe
chanceofvarnishdepositsinthefuelsystem,usefuel
stabilizeratalltimes.

FillingtheFuelTank

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundeachfueltankcapandremovethecap.

3.Addunleadedregulargasolinetobothfueltanks,
untilthelevelis1/4to1/2inch(6mmto13mm)
belowthebottomofthellerneck.

Thisspaceinthetankallowsgasolinetoexpand.
Donotllthefueltankscompletelyfull.

4.Installfueltankcapssecurely.

5.Wipeupanygasolinethatmayhavespilled.

•Ifagasolinedispensernozzlemustbeused,
keepthenozzleincontactwiththerimof
thefueltankorcontaineropeningatall
timesuntilfuelingiscomplete.

Gasolineisharmfulorfatalifswallowed.
Long-termexposuretovaporscancauseserious
injuryandillness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor
conditioneropening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check
theoillevelintheenginecrankcase;refertoChecking
OilLevelinEngineMaintenance,page26

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe
safetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.

•Keepsgasolinefreshduringstorageof90daysor
less.Forlongerstorageitisrecommendedthatthe
fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting

12

Operatingonwetgrassorsteepslopescan
causeslidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers,
whichmayresultinseriousinjury,deathor
drowning.

Thereisnorolloverprotectionwhentheroll
barisdown.

Alwayskeeptherollbarintheraisedandlocked
positionandusetheseatbelt.

Readandfollowtherolloverprotection
instructionsandwarnings.

Toavoidlossofcontrolandpossibilityof
rollover:

Thismachineproducessoundlevelsinexcess
of85dBAattheoperatorsearandcancause
hearinglossthroughextendedperiodsof
exposure.

Wearhearingprotectionwhenoperatingthis
machine.

Useprotectiveequipmentforyoureyes,hearing,feet,
andhead.

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan
15degrees.

•Reducespeedanduseextremecautionon
slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure8

1.Warningwearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe
machineorleaveitunattended.

SettingtheParkingBrake

1.Movethemotioncontrollevers(Figure14)outto
theneutrallockposition.

2.Pullupandbackontheparkingbrakelevertoset
theparkingbrake(Figure9).Theparkingbrake
levershouldstayrmlyintheengagedposition.

Parkingbrakemaynotholdmachineparked
onaslopeandcouldcausepersonalinjuryor
propertydamage.

Figure7

1.SafeZone-usetheZMasterhereonslopeslessthan
15degreesoratareas.

2.Usewalkbehindmowerand/orhandtrimmerneardrop-offs
andwater.

3.Water

Donotparkonslopesunlesswheelsare
chockedorblocked

ReleasingtheParkingBrake

Pushforwardanddownontheparkingbrakeleverto
releasetheparkingbrake(Figure9).

13

1.Parkingbrake–Set/ON

Figure9

2.Parkingbrake–

5.Movethethrottlecontroltothefastpositionbefore
startingacoldengine(Figure11).

Released/OFF

1.Chokeon

2.Chokeoff4.Throttlefast

Figure11

3.Throttleslow

StartingandStoppingthe
Engine

StartingtheEngine

1.Sitontheseatandmovethemotioncontrolsto
neutrallockedposition.

2.Settheparkingbrake;refertoSettingtheParking
Brake.

3.MovethePTO(powertakeoff)switchtotheOff
position(Figure10).

Figure10

1.PTOon(knobout)2.PTOoff(knobin)

6.TurntheignitionkeytoStart.Whentheengines
starts,releasethekey(Figure12).

Important:Donotengagestarterformore
than10secondsatatime.Ifenginefailsto
startallow30secondcool-downperiodbetween
attempts.Failuretofollowtheseinstructions
canburnoutstartermotor.

Figure12

1.Off3.Start

2.Run

7.Aftertheenginestarts,movethechoketooff
(Figure11).Iftheenginestallsorhesitates,move
thechokebacktoonforafewseconds,thenmove
thethrottlelevertodesiredsetting.Repeatthisas
required.

4.Movethechokecontroltotheonpositionbefore
startingacoldengine(Figure11).

Note:Awarmorhotenginemaynotrequire
choking.Afterenginestarts,movechokecontrolto
Runposition.

StoppingtheEngine

1.PushthePTOtotheoffposition(Figure10).

2.Movethethrottlelevermidwaybetweentheslow
andfastpositions(Figure11).

14

3.Lettheengineidlefor60seconds.

4.Turntheignitionkeytotheoffpositionandremove
thekey(Figure12).

5.Closethefuelshutoffvalvebeforetransportingor
storingthemachine(Figure6).

Important:Makesurethatthefuelshutoff
valveisclosedbeforetransportingorstoring
themachine,asfuelleakagemayoccur.Setthe
parkingbrakebeforetransporting.Makesure
toremovethekeyasthefuelpumpmayrun
andcausethebatterytolosecharge.

Figure13

1.PTO-On(knobout)2.PTO-Off(knobin)

DisengagingthePTO

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileit
isunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

OperatingthePowerTakeOff
(PTO)

Thepowertakeoff(PTO)switchstartsandstopsthe
mowerbladesandanypoweredattachments.

EngagingthePTO

1.Iftheengineiscold,allowtheenginetowarmup5
to10minutesbeforeengagingthePTO.

2.Whileseatedintheseat,releasethepressureonthe
tractioncontrolleversandplaceinneutral.

3.Placethethrottleinthefastposition.

Todisengage,pushthePTOswitchtotheoffposition
(Figure13).

TheSafetyInterlockSystem

Ifsafetyinterlockswitchesaredisconnected
ordamagedthemachinecouldoperate
unexpectedlycausingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

UnderstandingtheSafetyInterlock
System

Thesafetyinterlocksystemisdesignedtopreventthe
enginefromstartingunless:

Note:EngagingthePTOwiththethrottleatthe
halforlesspositionwillcauseexcessiveweartothe
drivebelts.

4.Pulloutonthepowertakeoff(PTO)switchto
engageit(Figure13).

•Youaresittingontheseat.

•Theparkingbrakeisengaged.

•Thepowertakeoff(PTO)isoff.

•Themotioncontrolleversareintheneutrallocked
position

Thesafetyinterlocksystemalsoisdesignedtostopthe
enginewhenthetractioncontrolsaremovedfromthe
lockedpositionwiththeparkingbrakeengagedorif
yourisefromtheseatwhenthePTOswitchison.

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

15

Note:Ifthesafetysystemdoesnotoperateas
describedbelow,haveanAuthorizedServiceDealer
repairthesafetysystemimmediately.

1.Sittingontheseat,engagetheparkingbrakeand
movethePTOtoon.Trystartingtheengine;the
engineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeand
movethePTOtooff.Moveeithermotioncontrol
lever(outofneutrallockedposition).Trystarting
theengine;theengineshouldnotcrank.Repeatfor
othercontrollever.

3.Sittingontheseat,engagetheparkingbrake,move
thePTOswitchtooffandmovethemotioncontrol
leverstoneutrallockposition.Nowstartthe
engine.Whiletheengineisrunning,releasethe
parkingbrake,movethePTOtoonandriseslightly
fromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move
thePTOswitchtooffandmovethemotioncontrol
leverstoneutrallockposition.Nowstarttheengine.
Whiletheengineisrunning,centereithermotion
controlandmove(forwardorreverse);theengine
shouldstop.Repeatforothermotioncontrol.

2.Movetheleverstothecenter,theun-locked
position.

3.Togoforward,slowlypushthemotioncontrol
leversforward(Figure14).

Note:Theenginewillkillifthetractioncontrol
leversaremovedwiththeparkingbrakeengaged.

Togostraight,applyequalpressuretobothmotion
controllevers(Figure14).

Toturn,movethemotioncontrollevertoward
neutralinthedirectionyouwanttoturn(Figure14).

Thefartheryoumovethetractioncontrolleversin
eitherdirection,thefasterthemachinewillmovein
thatdirection.

Tostop,pullthemotioncontrolleverstothecenter
position.

5.Sittingontheseat,disengagetheparkingbrake,
movethePTOswitchtooffandmovethemotion
controlleverstoneutrallockposition.Trystarting
theengine;theengineshouldnotcrank.

DrivingForwardorBackward

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

Machinecanspinveryrapidly .Operatormay
losecontrolofmachineandcausepersonal
injuryordamagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

DrivingForward

1.Releasetheparkingbrake;refertoReleasingthe
ParkingBrakeinOperation,page11.

Figure14

1.Motioncontrol
lever-neutrallockposition

2.Centerun-lockposition

3.Forward

4.Backward

DrivingBackward

1.Movetheleverstothecenter,un-lockedposition.

2.Togobackward,slowlypullthemotioncontrol
leversrearward(Figure14).

Togostraight,applyequalpressuretobothmotion
controllevers(Figure14).

16

Toturn,releasepressureonthemotioncontrollever
towardthedirectionyouwanttoturn(Figure14).

Tostop,pushthemotioncontrolleverstothe
neutralposition.

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers
tothecenterpositionandmovethemouttothelocked
position,disengagethepowertakeoff(PTO),andturn
theignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;refer
toSettingtheParkingBrakeinOperation,page11.
Remembertoremovethekeyfromtheignitionswitch.

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethetractorwhileit
isunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

AdjustingtheHeight-of-Cut

Theheight-of-cutisadjustedfrom1to5inch
(25to127mm)in1/4inch(6mm)incrementsby
relocatingtheclevispinintodifferentholelocations.

1.Raisetheheight-of-cutlevertothetransport
position(alsothe5inch(127mm)cuttingheight
position)(Figure15).

2.Toadjust,removetheclevispinfromthe
height-of-cutbracket(Figure15).

3.Selectaholeintheheight-of-cutbracket
correspondingtotheheight-of-cutdesiredand,
inserttheclevispin(Figure15).

4.Movethelevertotheselectedheight.

Figure15

1.Heightofcutholes2.ClevisPin

UsingtheLiftAssistPedal

Theliftassistpedalisusedforraisingthemowerdeck.
Thisallowsforeasierraisingofthemowerdeck.

1.Placeyourfootontoliftassistlever.

2.Pressontheliftassistleverwhilepullinguponthe
height-of-cutlever(Figure16).

Figure16

1.LiftAssistpedal2.Height-of-cutlever

17

AdjustingtheAnti-Scalp
Rollers

Wheneveryouchangetheheight-of-cut,adjustthe
heightoftheanti-scalprollers.

1.DisengagethePTO,movethemotioncontrol
leverstotheneutrallockedpositionandsetthe
parkingbrake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Afteradjustingtheheight-of-cut,adjusttherollers
byremovingtheangenut,bushing,spacer,and
bolt(Figure17).

4.Selectaholesotheanti-scalprollerispositionedto
thenearestcorrespondingheight-of-cutdesired.

5.Installtheangenutbushing,spacer,andbolt.
Torqueto40-45ft-lb(54-61N•m)(Figure17).

6.Repeatthisadjustmentontheotheranti-scalp
rollers.

1.Adjustmentbolts

Figure18

2.Seat

Figure17

1.Bolt4.Anti-scalproller

2.Anti-scalprollerbracket

3.FlangeNut6.Bushing

5.Spacer

PositioningtheSeat

PushingtheMachinebyHand

Important:Alwayspushthemachinebyhand.

Nevertowthemachinebecausedamagemay
occur.

ToPushtheMachine

1.Disengagethebladecontrolswitchandmovethe
controlleverstotheneutrallockedpositionand
applytheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Pullthetwobypassleversrearwardandpushthem
totheoutsideintotheslottolockthemintoplace.
(Figure19).

Note:Makesurebothbypassleversaredisengaged
beforepushingthemachine.

4.Disengagetheparkingbraketopushthemachine.

Theseatcanmoveforwardandbackward.Positionthe
seatwhereyouhavethebestcontrolofthemachine
andaremostcomfortable.

1.Raisetheseatandloosentheadjustmentbolts
(Figure18).

2.Movetheseattothedesiredpositionandtighten
thebolts.

18

G004250

1

1

3

21

Withoutthegrassdeector,dischargecover,
orcompletegrasscatcherassemblymounted
inplace,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebriswill
causeinjuryordeath.

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

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytoclearthedischargeareaor
mowerbladesunlessyoumovethepower
takeoff(PTO)totheoffposition,rotatethe
ignitionkeytooffandremovethekey.

•Makesurethegrassdeectorisinthedown
position.

TransportingMachines

Useaheavy-dutytrailerortrucktotransportthe
machine.Ensurethatthetrailerortruckhasall

Figure19

1.Bypasslever

2.Topviewofengine

3.Slot

ToOperatetheMachine

Pusheachbypasslevertotheinsideandpushthem
forward(Figure19).

Note:Themachinewillnotdriveunlessthebypass
leversarepushedforward.

UsingtheSideDischarge

necessarylightingandmarkingasrequiredbylaw .
Pleasecarefullyreadallthesafetyinstructions.
Knowingthisinformationcouldhelpyou,yourfamily ,
petsorbystandersavoidinjury.

Totransportthemachine:

•Lockthebrakeandblockthewheels.

•Securelyfastenthemachinetothetrailerortruck
withstraps,chains,cable,orropes.

•Secureatrailertothetowingvehiclewithsafety
chains.

Drivingonthestreetorroadwaywithoutturn
signals,lights,reectivemarkings,oraslow
movingvehicleemblemisdangerousandcan
leadtoaccidentscausingpersonalinjury.

Themowerhasahingedgrassdeectorthatdisperses
clippingstothesideanddowntowardtheturf.

Donotdrivemachineonapublicstreetor
roadway.

19

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor
trucks.Onefullwidthrampthatiswideenoughto
extendbeyondthereartiresisrecommendedinsteadof
individualrampsforeachsideoftheunit(Figure20).
Thelowerrearsectionofthetractorframeextends
backbetweentherearwheelsandservesasastopfor
tippingbackward.Havingafullwidthrampprovides
asurfacefortheframememberstocontactifthe
unitstartstotipbackward.Ifitisnotpossibletouse
onefullwidthramp,useenoughindividualrampsto
simulateafullwidthcontinuousramp.

Therampshouldbelongenoughsothattheangles
donotexceed15degrees(Figure20).Asteeperangle
maycausemowercomponentstogetcaughtastheunit
movesfromramptotrailerortruck.Steeperangles
mayalsocausetheunittotipbackward.Ifloadingon
ornearaslope,positionthetrailerortrucksoitison
thedownsideoftheslopeandtherampextendsupthe
slope.Thiswillminimizetherampangle.Thetraileror
truckshouldbeaslevelaspossible.

Figure20

1.Trailer3.Notgreaterthan
15degrees

2.Fullwidthramp4.Fullwidthrampsideview

Important:DoNotattempttoturntheunitwhile
ontheramp;youmaylosecontrolanddriveoff
theside.

Avoidsuddenaccelerationwhendrivinguparampand
suddendecelerationwhenbackingdownaramp.Both
maneuverscancausetheunittotipbackward.

Loadingaunitontoatrailerortruckincreases
thepossibilityofbackwardtip-overandcould
causeseriousinjuryordeath.

•Useextremecautionwhenoperatingaunit
onaramp.

•Useonlyasingle,fullwidthramp;DoNot
useindividualrampsforeachsideofthe
unit.

•Ifindividualrampsmustbeused,use
enoughrampstocreateanunbrokenramp
surfacewiderthantheunit.

OperatingTips

FastThrottleSetting

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

CuttingaLawnfortheFirstTime

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

•Donotexceeda15degreeanglebetween
rampandgroundorbetweenrampand
trailerortruck.

•Avoidsuddenaccelerationwhiledrivingunit
uparamptoavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking
unitdownaramptoavoidtippingbackward.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.
Cuttingmorethanthatisnotrecommendedunless
grassissparse,oritislatefallwhengrassgrowsmore
slowly.

20

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding
straight.Thisalsohelpsdisperseclippingswhich
enhancesdecompositionandfertilization.

MowatCorrectIntervals

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

CuttingSpeed

Toimprovecutquality,useaslowergroundspeedin
certainconditions.

AvoidCuttingTooLow

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

Ifthecuttingwidthofthemoweriswiderthanthe
moweryoupreviouslyused,raisethecuttingheightto
ensurethatuneventurfisnotcuttooshort.

LongGrass

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

WhenStopping

Ifthemachine’sforwardmotionmustbestoppedwhile
mowing,aclumpofgrassclippingsmaydropontoyour
lawn.T oavoidthis,moveontoapreviouslycutarea
withthebladesengaged.

KeeptheUndersideoftheMower
Clean

Cleanclippingsanddirtfromtheundersideofthe
moweraftereachuse.Ifgrassanddirtbuildupinside
themower,cuttingqualitywilleventuallybecome
unsatisfactory.

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseason
becauseasharpbladecutscleanlywithouttearingor

21

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst250hours

Beforeeachuseordaily

Every25hours

Every50hours

Every100hours

MaintenanceProcedure

•Checkforanyloosefastenersandtightenthem.

•Changetheengineoil.

•Tightenthewheellugnuts.

•Checkthehydraulicuid.

•Changethehydraulicltersandoil.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Cleantheairintakescreen.

•Checkthebrake.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Cleanfoamaircleanerelement.(moreoftenindirtyordustyconditions)

•Checkthepaperaircleanerelement.(moreoftenindirtyordustyconditions)

•Checkthetirepressure.

•Checkpumpdrivebelt.

•Checkthehydraulicuid.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Checkthesparkplugs.

•Checkandcleanenginecoolingnsandshrouds.

•Inspectallbeltsforcracksandwear.

Every150hours

Every200hours

Every500hours

Yearly

Important:Refertoyour

•Lubricatethemachinewithlightoil

•Replacethepaperaircleanerelement.

•Replacetheoillter

•Replacethefuellter.

•Adjustthecasterpivotbearing.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions)

•Lubricatethecasterwheelhubs.

•Changethehydraulicltersandoil.

Engine Operator’ s Man ual

foradditionalmaintenanceprocedures.

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously
injureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthewirefromthesparkplug(s)beforeyoudoany
maintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.

Lubrication

frequentlywhenoperatingconditionsareextremely
dustyorsandy.

GreasingandLubrication

LubricatethemachinewhenshownontheCheck
ServiceReferenceAiddecal(Figure21).Greasemore

GreaseType:General-purposegrease.

22

HowtoGrease

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

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

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

5.Wipeupanyexcessgrease.

GreasingtheFrontCasterPivots

ServiceInterval:Yearly(moreoftenindirtyordusty

conditions)

1.Removethedustcapandadjustthecasterpivots.
Keepthedustcapoffuntilgreasingisdone.Referto
AdjustingtheCasterPivotBearinginDriveSystem
Maintenance,page33.

Figure21

2.Removethehexplug.Threadagreasezerkintothe
hole.

3.Pumpgreaseintothezerkuntilitoozesoutaround
thetopbearing.

4.Removethegreasezerkinthehole.Installthehex
plugandcap.

WheretoAddGrease

LubricatethegreasettingsasshownontheCheck
ServiceReferenceAiddecal(Figure21).

GreaseandoilthelinkagesasshowninFigure23and
Figure24.

Figure22

Brakehandlepivot

WheretoAddLightOilorSpray
Lubrication

ServiceInterval:Every150hours(Referto

Lubrication).

Lubricatethemachineinthefollowingareaswithspray
typelubricantorlightoil.

•Seatswitchactuator.

•Brakecontrollinks.

•Motioncontrolpivots.

23

Figure23

4.Removethennutandboltholdingthecasterwheel
tothefrontcasterfork(Figure25).

5.Removethesealguardfromthewheelhub
(Figure25).

Figure24

LubricatingtheCasterWheel
Hubs

ServiceInterval:Yearly

Note:Whenperformingthisprocedure,theoldseals
willneedtobereplacedwithnewseals.Contactan
AuthorizedServiceDealerforthecorrectseals.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

Figure25

1.Casterfork4.Casterwheel

2.Bolt5.Nut

3.Sealguard

6.Removeoneofthespacernuts(withwrenchats)
fromtheaxle(Figure27).

Note:Threadlockingadhesivehasbeenapplied
tothespacernuts.

7.Removetheaxlewithoutremovingtheopposite
spacernut(Figure27).

8.Removethesealsandinspectthebearingsforwear
ordamage.Replacethebearingsifneeded.

9.Packthebearingswithgeneralpurposegrease.

10.Insertthebearingandanewsealintothewheel
(Figure27).

Note:Donotinstallthenutallthewayontothe
axle.

11.Ifbothspacernutswereremovedfromtheaxle,
applythreadlockingadhesivetothespacernut.
Installthespacernutsontotheaxleleavingan1/8
inch(3mm)ofthenutpasttheaxle(Figure26).

3.Raisethefrontofthemachineandsupportitwith
jackstands.

24

Figure26

1.1/8inch(3mm)ofthenutpasttheaxle

12.Installtheassemblednutandaxleintothewheelon
thesidewiththebearingandanewseal(Figure27).

13.Placethewheelwiththeopenendfacingupandll
theareainsidethewheelwithmulti-purposegrease.

14.Installthesecondbearingandanewsealintothe
wheel(Figure27).

15.Applythreadlockingadhesivetothesecondspacer
nutandinstallitontotheaxlewiththewrenchats
facingoutward.

16.Torquethespacernutto75-80in-lb(8-9N⋅m)then
loosenitandtorqueitto20–25in-lb(2-3N⋅m).
Makesuretheaxledoesnotextendpasteithernut
(Figure26).

Figure27

1.Spacernut4.Casterwheel

2.Bearingseal(newseals
required)

3.Bearing

5.Nutandaxleassembled

17.Installthesealguardsoverthewheelhubsandinsert
thewheelintothecasterfork(Figure25).

18.Installthecasterboltandtightenthenut(Figure25).

Important:Checkthebearingadjustmentoften
topreventsealandbearingdamage.Spinthe
castertire.Thetireshouldnotspinfreelymore
than1to2revolutionsorhaveanyside-to-side
playbetweenthecasterfork.Ifthewheelspins
freely,adjustthetorqueonthespacernutuntil
thereisaslightamountofdrag.

25

EngineMaintenance

ServicingtheAirCleaner

Important:Donotoilthefoamorpaperelement.

Note:Servicetheaircleanermorefrequently(every

fewoperatinghours)iftheoperatingconditionsare
extremelydustyorsandy .

RemovingtheFoamandPaper
Elements

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Cleanaroundtheaircleanertopreventdirt
fromgettingintotheengineandcausingdamage
(Figure28).

4.Unscrewthecoverknobandremovetheaircleaner
cover(Figure28).

5.Removethe2wingnutsandremovetheaircleaner
assembly(Figure28).

6.Carefullypullthefoamelementoffthepaper
element(Figure28).

Figure28

1.Engine4.Foamelement

2.Cover

3.Wingnut

5.Paperelement

6.Coverknob

CleaningtheFoamAirCleanerElement

ServiceInterval:Every25hours(moreoftenindirty

ordustyconditions)

1.Washthefoamelementinliquidsoapandwarm
water.Whentheelementisclean,rinseitthoroughly.

2.Drytheelementbysqueezingitinacleancloth.

Important:Replacethefoamelementifitis
tornorworn.

ServicingthePaperAirCleaner
Element

ServiceInterval:Every50hours(moreoftenindirty

ordustyconditions)

Every200hoursoryearly,whichever
occursrst.

1.Donotcleanthepaperlter,replaceit.(Figure28).

2.Inspecttheelementfortears,anoilylm,ordamage
totherubberseal.

3.Replacethepaperelementifitisdamaged.

26

InstallingtheFoamandPaperElements

Important:Topreventenginedamage,always

operatetheenginewiththecompletefoamand
paperaircleanerassemblyinstalled.

1.Carefullyslidethefoamelementontothepaperair
cleanerelement(Figure28).

2.Placetheaircleanerassemblyontotheaircleaner
baseandsecureitwiththe2wingnuts(Figure28).

3.Placetheaircleanercoverintopositionandtighten
thecoverknob(Figure28).

ServicingtheEngineOil

Note:Changetheoilmorefrequentlywhenthe

operatingconditionsareextremelydustyorsandy .

OilType:Detergentoil(APIserviceSF,SG,SH,orSJ)

CrankcaseCapacity:58ounces(1.7liter)withthelter
removed;51ounces(1.5liter)withoutthelterremoved

Viscosity:Refertothetablebelow

Figure30

1.Oildipstick

2.Fillertube

5.Unscrewtheoildipstickandwipetheendclean
(Figure30).

6.Slidetheoildipstickfullyintothellertube,butdo
notthreadontotube(Figure30).

7.Pullthedipstickoutandlookatthemetalend.Ifthe
oillevelislow,slowlypouronlyenoughoilintothe
llertubetoraisetheleveltotheFullmark.

Important:Donotoverllthecrankcasewith
oilandruntheengine;enginedamagecan
result.

ChangingtheOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirty
ordustyconditions)

Figure29

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface.

2.DisengagethePTO ,turntheignitionkeytooff,and
removethekey.

3.Waitforallmovingpartstostopbeforeleavingthe
operatingpositionandthenchockorblocktires.

4.Cleanaroundtheoildipstick(Figure30)sothatdirt
cannotfallintothellerholeanddamagetheengine.

1.Starttheengineandletitrunveminutes.This
warmstheoilsoitdrainsbetter.

2.Parkthemachinesothatthedrainsideisslightly
lowerthantheoppositesidetoassuretheoildrains
completely.

3.DisengagethePTOandsettheparkingbrake.

4.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

5.Slidethedrainhoseovertheoildrainvalve.

6.Placeapanbelowthedrainhose.Rotateoildrain
valvetoallowoiltodrain(Figure31).

7.Whenoilhasdrainedcompletely,closethedrain
valve.

8.Removethedrainhose(Figure31).

Note:Disposeoftheusedoilatarecyclingcenter.

27

3.Applyathincoatofnewoiltotherubbergasketon
thereplacementlter(Figure32).

4.Installthereplacementoilltertothelteradapter,
turntheoillterclockwiseuntiltherubbergasket
contactsthelteradapter,thentightenthelteran
additional3/4turn(Figure32).

5.Fillthecrankcasewiththepropertypeofnewoil;
refertoServicingtheEngineOil.

6.Runtheengineforabout3minutes,stoptheengine,
andcheckforoilleaksaroundtheoillter.

7.Checktheengineoillevelandaddoilifneeded.

ServicingtheSparkPlugs

ServiceInterval/Specication

Figure31

1.Oildrainvalve2.Oildrainhose

9.Slowlypourapproximately80%ofthespeciedoil
intothellertube(Figure30).

10.Checktheoillevel;refertoCheckingtheEngineOil
Level.

11.SlowlyaddtheadditionaloiltobringittotheFull
mark.

ChangingtheOilFilter

ServiceInterval:Every200hoursoreveryotheroil

change.

Note:Changetheoilltermorefrequentlywhenthe
operatingconditionsareextremelydustyorsandy .

1.Draintheoilfromtheengine;refertoChangingthe
EngineOil.

2.Removetheoldlter(Figure32).

Ensurethattheairgapbetweenthecenterandside
electrodesiscorrectbeforeinstallingthesparkplug.
Useasparkplugwrenchforremovingandinstallingthe
sparkplugsandagappingtool/feelergaugetocheckand
adjusttheairgap.Installanewsparkplugsifnecessary.

Type:Champion®RCJ8YorequivalentAirGap:

0.030inch(0.75mm)

RemovingtheSparkPlugs

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Disconnectthewiresfromthesparkplugs
(Figure33).

1.Oillter

Figure32

Figure33

1.Spark-plugwire/sparkplug

4.Cleanaroundthesparkplugstopreventdirtfrom
fallingintotheengineandpotentiallycausing

2.Adapter

damage.

5.Removethesparkplugsandthemetalwashers.

28

CheckingtheSparkPlugs

ServiceInterval:Every100hours

1.Lookatthecenterofthesparkplugs(Figure34).
Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly .Ablackcoatingonthe
insulatorusuallymeansthattheaircleanerisdirty.

2.Ifneeded,cleanthesparkplugwithawirebrushto
removecarbondeposits.

FuelSystem
Maintenance

DrainingtheFuelTank

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

•Draingasolinefromthefueltankwhenthe
engineiscold.Dothisoutdoorsinanopen
area.Wipeupanygasolinethatspills.

•Neversmokewhendraininggasoline,and
stayawayfromanopenameorwherea
sparkmayignitethegasolinefumes.

Figure34

1.Centerelectrodeinsulator3.Airgap(nottoscale)

2.Sideelectrode

Important:Alwaysreplacethesparkplugs
whenithasablackcoating,wornelectrodes,
anoilylm,orcracks.

3.Checkthegapbetweenthecenterandsideelectrodes
(Figure34).Bendthesideelectrode(Figure34)if
thegapisnotcorrect.

InstallingtheSparkPlugs

1.Installthesparkplugsandthemetalwasher.Ensure
thattheairgapissetcorrectly.

2.Tightenthesparkplugsto16ft-lb(22N•m).

3.Connectthewirestothesparkplugs(Figure34).

1.Parkthemachineonalevelsurface,toensurethat
thefueltankdrainscompletely.

2.Disengagethebladecontrolswitchandmovethe
controlleverstotheneutrallockedpositionand
applytheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

4.Closethefuelshut-offvalvelocatedunderthefront
ofthefueltank.

5.Loosenthehoseclampatthefuellterandslideit
upthefuellineawayfromthefuellter(Figure35).

6.Pullthefuellineoffofthefuellter(Figure35).

7.Openthefuelshut-offvalve.Allowgasolinetodrain
intoagascanordrainpan.

Note:Nowisthebesttimetoinstallanewfuel
lterbecausethefueltankisempty .

ReplacingtheFuelFilter

ServiceInterval:Every200hoursoryearly ,whichever

occursrst.

Neverinstalladirtylterifitisremovedfromthefuel
line.

1.Disengagethebladecontrolswitchandmovethe
controlleverstotheneutrallockedpositionand
applytheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

29

3.Closethefuelshut-offvalvelocatedunderthefront
ofthefueltank.

4.Squeezetheendsofthehoseclampstogetherand
slidethemawayfromthelter(Figure35).

ElectricalSystem
Maintenance

5.Removethelterfromthefuellines.

6.Installanewlterandmovethehoseclampsclose
tothelter(Figure35).

Important:Installtheltersothedirectionof
theowarrowisconsistentwiththeowoffuel;
fromthegastanktotheengine.

7.Openthefuelshut-offvalve.

Figure35

1.Fuellter

2.Hoseclamp

3.Fuelline

ServicingtheBattery

Warning

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith
skin,eyesorclothing.Wearsafetyglassesto
shieldyoureyesandrubberglovestoprotect
yourhands.

RemovingtheBattery

Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponentscausing
sparks.Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,do
notallowthebatteryterminalstotouchany
metalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

30

Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.

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

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

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Unlatchtheseatandtilttheseatup.

4.Firstdisconnectthenegativebatterycableand
groundwirefromthenegative(-)batteryterminal
(Figure36).

5.Slidetheredterminalbootoffthepositive(red)
batteryterminal.Thenremovethepositive(red)
batterycable(Figure36).

Figure36

1.Battery7.J-bolts

2.Positivebatterypost

3.Negativebatterypost

4.Terminalboot10.Negativebatterycable

5.Batteryclamp

6.Wingnut(1/4inch)

8.Bolt(1/4x3/4inch)

9.Groundwire

11.Locknut(1/4inch)

12.Positivebatterycable

6.Removebothwingnuts(1/4inch)securingthe
batteryclamp(Figure36).

7.Removethebattery.

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts
towardtheengine(Figure36).

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

3.Theninstallthenegativebatterycableandground
wiretothenegative(-)batteryterminal.

4.Securethecableswith2bolts(1/4x3/4inch),
2washers(1/4inch),and2locknuts(1/4inch)
(Figure36).

5.Slidetheredterminalbootontothepositive(red)
batterypost.

6.SecurebatterywithJ-bolts,holddownclampand
2washers(1/4inch),and2wingnuts(1/4inch)
(Figure36).

31

ChargingtheBattery

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

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

1.Chargebatteryfor10to15minutesat25to30amps
or30minutesat4-6amps.

2.Whenthebatteryisfullycharged,unplugthecharger
fromtheelectricaloutlet,thendisconnectthe
chargerleadsfromthebatteryposts(Figure37).

2.Toreplacethefuses,pulloutonthefusetoremove
it.

3.Installanewfuse(Figure38).

Figure38

1.Fuselocation

2.Main,20amp

3.Chargecircuit,20amp

Figure37

3.Installthebatteryinthemachineandconnectthe
batterycables;refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery
disconnected,electricaldamagemayoccur.

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires
nomaintenance,however,ifafuseblowscheck
component/circuitformalfunctionorshort.

Fuse:

•Main,F1-20amp,blade-type

•Chargecircuit,F2-20amp,blade-type

1.Raisetheseattogainaccesstothefusesontheleft
sideofthemachine(Figure38).

32

DriveSystem
Maintenance

CheckingtheTirePressure

ServiceInterval:Every50hoursormonthly ,whichever

occursrst.

Checkthepressureatthevalvestemafterevery
50operatinghoursormonthly,whicheveroccursrst
(Figure39).

Maintaintheairpressureinthereartiresat13psi(90
kPa).Uneventirepressurecancauseunevencut.Check
thetireswhentheyarecoldtogetthemostaccurate
pressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddo
notrequireairpressuremaintenance.

Figure40

1.SpringWashers3.DustCap

2.LockNut

Figure39

AdjustingtheCasterPivot
Bearing

ServiceInterval:Every500hours

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removethedustcapfromcasterandtightenlock
nut(Figure40).

4.Tightenthelocknutuntilthespringwashersareat
andthenbackoffa1/4turntoproperlysetthe
pre-loadonthebearings(Figure40).

Important:Makesurespringwashersare
installedcorrectlyasshowninFigure40.

5.Installthedustcap(Figure40).

33

CoolingSystem
Maintenance

BrakeMaintenance

ServicingtheBrakes

CleaningtheAirIntakeScreen

ServiceInterval:Beforeeachuseordaily

Beforeeachuseremoveanybuild-upofgrass,dirt
orotherdebrisfromthecylinderandcylinderhead
coolingns,airintakescreenonywheelend,and
carburetor-governorleversandlinkage.Thiswillhelp
insureadequatecoolingandcorrectenginespeedand
willreducethepossibilityofoverheatingandmechanical
damagetotheengine.

CleaningtheEngineCooling
System

ServiceInterval:Every100hoursoryearly ,whichever

occursrst.

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Removetheairintakescreen,recoilstarterandfan
housing(Figure41).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing
(Figure41).

Beforeeachuse,checkthebrakesonbothalevelsurface
andslope.

Alwayssettheparkingbrakewhenyoustopthemachine
orleaveitunattended.Iftheparkingbrakedoesnot
holdsecurely ,seeanAuthorizedServiceDealerfor
maintenance.

CheckingtheBrake

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengagethe
bladecontrol(PTO).

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Applytheparkingbrake.Thewheelsmustlock
whenyoutrytopushthemachineforward.

4.Ifthewheelsdonotlock,seeanAuthorizedService
Dealerformaintenance.

5.Releasethebrakesandmovetheneutral/brakelocks
totheneutralposition.Thewheelsshouldrotate
freely,ifnot;seeanAuthorizedServiceDealerfor
maintenance.

Figure41

1.Airintakescreen4.Bolt

2.Fanhousing5.Nut

3.Recoilstarter

34

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every100hours—Inspectallbelts

forcracksandwear.

Checkbeltsforcracks,frayededges,burnmarksorany
otherdamage.Replacedamagedbelts.

ReplacingtheMowerBelt

Thesignsofawornmowerbeltaresquealingwhilethe
beltisrotating,bladesslippingwhileyouarecutting
grass,frayedbeltedges,burnmarks,andcracks.Replace
themowerbeltifyoudetectanyofthesesigns.

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Remove2boltsandwashersineachbeltcoverand
removethebeltcoversovertheoutsidespindles
(Figure44).

Figure43

40inchMower

1.Fixedidlerpulley3.Mowerbelt

2.Leftspindlepulley4.Spring-loadedidlerarm

8.Installthebeltcoversovertheoutsidespindles
(Figure44).

Note:Non-commercialownerswillneedtoinstall
thefrontwasherandboltthatholdsthebeltcover
inplace.

4.Pullontheidlerarmtorelievethebelttensionon
theleftspindlepulley(Figure42orFigure43).

5.Removetheoldbelt.

6.Installthenewbeltaroundthepulleys(Figure42
orFigure43).

7.Installthebeltontothespringloadedidlerpulley.

Figure42

34inchMower

1.Fixedidlerpulley3.Mowerbelt

2.Leftspindlepulley4.Spring-loadedidlerarm

Figure44

40inchmowershown

1.Leftbeltcover

2.Rightbeltcover4.Bolt

3.Washer

CheckingandReplacingthe
PumpDriveBelt

ServiceInterval:Every50hours—Checkpumpdrive

belt.

1.Pushtheseatforwadandlocatethepumpdrivebelt.

35

Note:Non-commercialownerswillneedtoloosen
theseatretainerclipthatholdstheseatinplace.

2.Checkthebeltforwearandreplaceitifneeded.

3.Toreplacethebelt,removetheboltfromtheclutch
stopandunplugtheclutchelectricalwire(Figure45).

ControlsSystem
Maintenance

AdjustingtheControlHandle

4.Pullontheidlerpulleytorelievethebelttensionon
theidlerpulley(Figure45).

5.Removethepumpdrivebeltfromtheengineandthe
hydraulicpumppulleys(Figure45).

6.Installthenewbeltaroundtheengineandthe
hydraulicpumppulleys(Figure45).

7.Pullthespring-loadedidlertothesideandalignthe
belt.

8.Releasethepressureonthespringloadedidler
(Figure45).

NeutralPosition

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedposition,andsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Loosentheboltsandcurvedwashersinstalledinthe
levers(Figure46).

4.Aligntheleversfronttorearpositionbybringthe
leverstogethertotheneutralpositionandslide
themuntiltheyarealigned,thentightenthebolts
(Figure47).

Figure45

1.Belt3.Enginepulley

2.Transmissionpump
pulleys

4.Springloadedidlerpulley

Figure46

36

Figure47

5.Iftheendsofthelevershitagainsteachother,adjust
theleversbyrotatingthemouttotheneutrallocked
positionandcarefullybendthemoutward.Repeat
thisstepasneeded.

AdjustingtheTracking

1.Ifthemachineturnsrightorleftwhenthehandles
arepushedforwardtogether,adjustthestoponthe
sideoppositethatthemachineturns.

2.Loosentheboltlocatedinfrontofthecontrollever.

3.Movethestopuntilthemachinedrivesstraight
(Figure48).

4.Tightentheboltlocatedinfrontofthecontrollever
(Figure48).

Figure48

1.Controllever3.Boltinfrontofthecontrol
lever

2.Stop

37

HydraulicSystem
Maintenance

ServicingtheHydraulic
System

CheckingtheHydraulicFluid

ServiceInterval:Aftertherst8hours

Every50hours

FluidType:Mobil115W-50syntheticmotoroilor
equivalentsyntheticoil.

Important:Useoilspeciedorequivalent.Other
uidscouldcausesystemdamage.

Note:Therearetwowaysofcheckingthehydraulic
oil;whentheoiliswarmorwhentheoiliscold.The
tankhastwolevelsdependingiftheoiliswarmorcold
(Figure49).

1.Positionthemachineonalevelsurfaceandsetthe
parkingbrake.

2.Cleantheareaaroundthehydraulictank(Figure49).

3.Ifthemachinehasnotbeenstartedandiscold,
ensuretheuidisuptothecoldlineonthesideof
thehydraulictank.

4.Ifthemachinehasbeenrunandisuptonormal
operatingtemperature,ensuretheuidisuptothe
hotlineonthesideofthehydraulictank.

5.Ifuidisneeded,removethecapfromtheller
neck(Figure49).

6.Adduidtothereservoiruntilitreachesthecoldor
hotlineofthetankdependingonthetemperature
oftheuid.

7.Installthecaponllerneck.

Figure49

1.Cap3.Colduidlevel-full

2.Bafe4.Hotuidlevel-full

Hydraulicuidescapingunderpressurecan
penetrateskinandcauseinjury.

•Ifhydraulicuidisinjectedintotheskin
itmustbesurgicallyremovedwithinafew
hoursbyadoctorfamiliarwiththistypeof
injury.Gangrenemayresultifthisisnot
done.

•Keepbodyandhandsawayfrompinhole
leaksornozzlesthatejecthighpressure
hydraulicuid.

•Usecardboardorpapertondhydraulic
leaks.

•Safelyrelieveallpressureinthehydraulic
systembeforeperforminganyworkonthe
hydraulicsystem.

•Makesureallhydraulicuidhosesand
linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretohydraulicsystem.

ReplacingtheHydraulicFiltersandOil

ServiceInterval:Aftertherst250hours

Yearly—Changethehydrauliclters
andoil.

38

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

Important:Donotsubstituteautomotiveoil
lterorseverehydraulicsystemdamagemay
result.

3.Locatethetwolters,oneundereachtransmission
andremovethelterguards.

4.Carefullycleantheareaaroundthelters.Itis
importantthatnodirtorcontaminationenterthe
hydraulicsystem(Figure50).

5.Unscrewtheltersandallowtheoiltodrainfrom
thedrivesystem(Figure50).

Important:Beforereinstallingnewlters,
applyathincoatofoilonthesurfaceofthe
ltersrubberseal.

6.Installthenewltersclockwiseuntilrubberseal
contactsthelteradapterandthentightenthelter
anadditional3/4to1fullturn.

changinglter),unlessitisfelttheoilhasbeen
contaminatedorbeenextremelyhot.Changing
theoilunnecessarilycoulddamagethehydraulic
systembyintroducingcontaminatesintothe
system.

7.Removetheventplugoneachtransmissionandll
throughthehydraulictank,whenoilcomesoutof
ventreinstallplug.T orquetheplugsto180in-lb
(244N⋅m).

8.Addoiluntilitreachesthecoldlineonthehydraulic
tank(Figure49).

9.Raisetherearofmachineupjustenoughtoallow
thedrivewheelstoturnfreelyandsupportitwith
jackstands.

10.Starttheengineandmovethethrottlecontrolahead
tothe1/2throttleposition.Disengagetheparking
brake.

11.Withthebypassvalveopenandtheenginerunning,
slowlymovethedirectionalcontrolinbothforward
andreverse5or6times.

12.Withthebypassvalveclosedandtheengine
running,slowlymovethedirectionalcontrolinboth
forwardandreversedirections5to6times.Stop
theengineandchecktheoillevel,andaddoilas
requiredtothehotline.

13.Repeatitems11and12asnecessaryuntilalltheair
iscompletelypurgedfromthesystem.Whenthe
transaxleoperatesatnormalnoiselevelsandmoves
smoothlyforwardandreverseatnormalspeeds,then
thetransaxleispurged.

1.Leftreartire

2.Hydrauliclter

Figure50

3.Ventplug

Important:Donotchangehydraulicsystem
oil(exceptforwhatcanbedrainedwhen

39

MowerDeck
Maintenance

LevelingtheMower

Important:Thereareonlythreemeasuring

positionsneededtolevelthemower.

1.Positionmoweronaatsurface.

2.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

3.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

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

5.Placetwothickblocksunderrearleftandrightlower
edgeofthemowerdecksotheweightofthedeck
restsontheblocks.

6.Lowerthemowertothe3inch(76mm)height-of-cut
position.

7.Loosentheboltsconnectingthetwochainsandthe
tworearbracketstothemower(Figure52).

8.Adjustthetworearboltssotheyareinthemiddleof
theslotlocatedinthepivotbracket(Figure52).

9.Adjusttheboltssotheendoftheboltisushwith
thenut.Thiswillallowthebushingtorollintheslot
inthemowerdeckbracket(Figure51).

10.Adjustthedischargesidefrontboltsoitisinthe
middleoftheslotlocatedinthepivotbracket
(Figure52).

11.Raisethemowerdeckandremovetheblocksholding
upthemowerdeck.

12.Adjusttheleftfrontboltinthepivotbracketsothe
chainhasnoslackinit.

13.Inspectthefourchains.Thechainsneedtohave
tension.

Note:Themowerdeckcuttingheightcanbe
adjusted.Loosentheheightofcutbracketandadjust
itforwardorbackwardtogetthecorrectheight.
Tightenthebracketaftertheadjustmentismade.

Figure51

1.Keeptheendofthebolt
ushwiththenut

2.Rearpivotbracket4.Bolt

3.Nut

Note:Whenproperlyadjusted,thefrontbladetip
willbea1/4inch(6mm)lowerfor34inchmowers
and3/16(4mm)lowerfor40inchmowersthanthe
rearbladetip.RefertoCheckingforBentBladesfor
theproceduretomeasurethebladetipheight.

14.Therightbladeatthefrontposition(Figure54or
Figure55)needstobethesameheightastheleft
bladeatthefrontposition.

Ifthereismorethanan1/8inch(3mm)difference
betweenleftandright,thenadjustthemounting
boltsintheslottolevelthemowerdecklefttoright.

40

Figure52

Leftsideshown

1.Pivotbracket3.Rearpivotbracket

2.Boltinstalledinthemiddleoftheslot

4.Frontpivotbracket

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason
becausesharpbladescutcleanlywithouttearingor
shreddingthegrassblades.Tearingandshreddingturns
grassbrownattheedges,whichslowsgrowthand
increasesthechanceofdisease.

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

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

•Inspectthebladeperiodicallyforwearor
damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe
Blades

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

41

InspectingtheBlades

A

1

G004621

A

A

2

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure53).Iftheedges
arenotsharporhavenicks,removeandsharpenthe
blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea
(Figure53).Ifyounoticeanydamage,wear,oraslot
forminginthisarea(Figure53),immediatelyinstalla
newblade.

Figure54

34inchMower

Figure53

1.CuttingEdge3.Wear/slotForming

2.CurvedArea

CheckingforBentBlades

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Rotatethebladesuntiltheendsfaceforwardand
backward(Figure54orFigure55).Measurefroma
levelsurfacetothecuttingedgeatpositionA,ofthe
blades(Figure54orFigure55).Notethisdimension.

1.Measureherefromblade
tohardsurface

40inchMower

1.Measureherefromblade
tohardsurface

2.PositionA

Figure55

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof
thebladesatthesamepositionasinstep3above.
Thedifferencebetweenthedimensionsobtainedin
steps3and4mustnotexceed1/16inch(1.5mm).
Ifthisdimensionexceeds1/16inch(1.5mm),
thebladeisbentandmustbereplaced;referto
RemovingtheBladesandInstallingtheBlades.

42

Abladethatisbentordamagedcouldbreak
apartandcouldseriouslyinjureorkillyouor
bystanders.

•Alwaysreplacebentordamagedbladewith
anewblade.

•Neverleorcreatesharpnotchesinthe
edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe
bladeisoutofbalanceorisbent.T oensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineTororeplacementblades.
Replacementbladesmadebyothermanufacturersmay
resultinnonconformancewithsafetystandards.

Contactwithasharpbladecancauseserious
injury.

Wearglovesorwrapsharpedgesoftheblade
witharag.

Figure56

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona
bladebalancer(Figure57).Ifthebladestaysina
horizontalposition,thebladeisbalancedandcanbe
used.Ifthebladeisnotbalanced,lesomemetaloff
theendofthesailareaonly(Figure58).Repeatthis
procedureuntilthebladeisbalanced.

Figure57

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure58).

1.Holdthebladeendusingaragorthickly-padded
glove.

2.Removethebladebolt,springdiskandbladefrom
thespindleshaft(Figure58).

SharpeningtheBlades

Whensharpeningblade,piecesofbladecould
bethrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpening
blade.

1.Usealetosharpenthecuttingedgeatbothends
oftheblade(Figure56).Maintaintheoriginalangle.
Thebladeretainsitsbalanceifthesameamountof
materialisremovedfrombothcuttingedges.

Important:Thecurvedpartoftheblademust
bepointingupwardtowardtheinsideofthe
mowertoensurepropercutting.

2.Installthespringdiskandbladebolt.Thespring
diskconemustbeinstalledtowardthebolthead
(Figure58).Torquethebladeboltto85-110ft-lb
(115-150N•m).

43

Figure58

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeTowardsBoltHead

ReplacingtheGrassDeector

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectsinthe
operator’sorbystander’sdirectionandresult
inseriousinjury.Also,contactwiththeblade
couldoccur.

•Neveroperatethelawnmowerunlessyou
installacoverplate,amulchplate,oragrass
chuteandcatcher.

•Makesurethegrassdeectorisinthedown
position.

Figure59

1.Bolt5.Locknut

2.GrassDeector6.Springinstalled

3.Spring

4.Spacer

7.Mowerdeck

1.Removethelocknut,bolt,springandspacerholding
thedeectortothepivotbrackets(Figure59).
Removethedamagedorworngrassdeector.

2.Placethespacerandspringontograssdeector.
Placeoneendofspringbehinddeckedge.

Note:Makesuretheendofthespringisinstalled
behindthedeckedgebeforeinstallingtheboltas
showninFigure59.

3.Installtheboltandnut.Placetheendofthespring
aroundthegrassdeector(Figure59).

Important:Thegrassdeectormustbeableto
lowerdownintoposition.Liftthedeectorup
totestthatitlowersintothefulldownposition.

44

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTO,movethemotioncontrollevers
totheneutrallockedpositionandsettheparking
brake.

2.Stoptheengine,removethekey,andwaitforall
movingpartstostopbeforeleavingtheoperating
position.

3.Raisethemowertothetransportposition.

4.Liftthefrontofthemachineandsupportthe
machineusingjackstands.

WasteDisposal

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

Storage

1.Disengagethepowertakeoff(PTO),settheparking
brake,andturntheignitionkeytoOff.Removethe
key.

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

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

3.Servicetheaircleaner;refertoServicingtheAir
CleanerinEngineMaintenance,page26.

4.Greasethemachine;refertoGreasingand
LubricationinLubrication,page22.

5.Changethecrankcaseoil;refertoServicingthe
EngineOilinEngineMaintenance,page26.

6.Checkthetirepressure;refertoCheckingtheTire
PressureinDriveSystemMaintenance,page33.

7.Changethehydrauliclter;refertoServicingthe
HydraulicSysteminHydraulicSystemMaintenance,
page38.

8.Chargethebattery;refertoServicingtheBatteryin
ElectricalSystemMaintenance,page30.

9.Scrapeanyheavybuildupofgrassanddirtfromthe
undersideofthemower,thenwashthemowerwith
agardenhose.

Note:RunthemachinewiththePTOengaged
andtheengineathighidlefor2to5minutesafter
washing.

10.Checktheconditionoftheblades;refertoServicing
theCuttingBladesinMowerDeckMaintenance,
page40.

11.Preparethemachineforstoragewhennon-use
occursover30days.Preparethemachineforstorage
asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions
fromthestabilizermanufacturer.Donotusean
alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshfuelandused
atalltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

45

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankinFuel
SystemMaintenance,page29.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly.Recycleasperlocal

codes.

Important:Donotstore
stabilizer/conditionedfuelover90days.

12.Checkandtightenallbolts,nuts,andscrews.Repair
orreplaceanypartthatisdamaged.

13.Paintallscratchedorbaremetalsurfaces.Paintis
availablefromyourAuthorizedServiceDealer.

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

46

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails
tokeeprunning.

Enginelosespower.

PossibleCauseCorrectiveAction

1.Bladecontrol(PTO)isengaged.1.Movethebladecontrol(PTO)to

2.Parkingbrakeisnoton.

3.Operatorisnotseated.3.Sitontheseat.

4.Batteryisdead.

5.Electricalconnectionsarecorrodedor
loose.

6.Fuseisblown.

7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.

1.Fueltankisempty .

2.Aircleanerisdirty .

3.Dirtinthefuellter.3.Replacethefuellter.

4.Dirt,water,orstalefuelisinthefuel
system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty .

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesabove
theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

7.Dirt,water,orstalefuelisinthefuel
system.

disengaged.

2.Settheparkingbrake.

4.Chargethebattery.

5.Checktheelectricalconnectionsfor
goodcontact.

6.Replacethefuse.

1.Fillthefueltankwithfuel.

2.Cleanorreplacetheaircleaner
element.

4.ContactanAuthorizedServiceDealer .

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe
coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer .

Engineoverheats.

Machinedoesnotdrive.

Abnormalvibration.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesabove
theengineareplugged.

1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.

2.Driveorpumpbeltisworn,looseor
broken.

3.Driveorpumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit

1.Cuttingblade(s)is/arebentor
unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley ,idlerpulley,or
bladepulley .

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe
coolingnsandairpassages.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer .

6.ContactanAuthorizedServiceDealer .

7.ContactanAuthorizedServiceDealer .

47

Problem

PossibleCauseCorrectiveAction

Unevencuttingheight.

Bladesdonotrotate.

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

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

3.Mowerisnotlevel.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower .

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

1.Drivebeltisworn,looseorbroken.

2.Drivebeltisoffpulley.

3.Deckbeltisworn,looseorbroken.3.Installanewdeckbelt.

4.Deckbeltisoffpulley.

5.Brokenormissingidlerspring.5.Replacethespring.

3.Levelthemowerfromside-to-sideand
front-to-rear.

6.ContactanAuthorizedServiceDealer .

1.Checkthebelttension.

2.Installthedrivebeltandcheck
adjustingshaftsandbeltguidesfor
correctposition.

4.Installthedeckpulleyandcheckthe
idlerpulley,idlerarmandspringfor
correctpositionandfunction.

48

Schematics

WireDiagram(Rev.A)

49

Notes:

50

Notes:

51

Landscape
Contractor

Equipment (LCE)

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, Toro Warranty Company, pursuant to an
agreement between them, jointly promise to repair the listed Toro Products if
defective in materials or workmanship. The following time periods apply from
the date of purchase:

This warranty applies to:

•

ProLine Mid-Size Mowers and Attachments

•

Z Master Mid-Mount ZRTs and Attachments

Components

Traction Unit Frame and Carrier Frame
All Spindles

Engines* and /Hydraulic System
Deck Shells (34 ″ -72 ″ )
Z500 Series Electric Clutch
Remaining Components

* S o m e e n g i n e s u s e d o n T o r o L C E P r o d u c t s a r e w a r r a n t e d b y t h e e n g i n e m a n u f a c t u r e r .

This warranty includes the cost of parts and labor, but you must pay
transportation costs.

Warranty Period

1 year
1 year

2 year

3 years Parts

2 years Labor

2 years
2 years
2 years

1 year

Instructions for Obtaining Warranty Service

If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at
their dealership. To locate a dealer convenient to you, access our website at
www.Toro.com. You may also call our Toro Customer Care Department
toll free at 888–865–5676 (U.S. Customers) or 888–865–5691 (Canada
customers).

2. Bring the product and your proof of purchase (sales receipt) to the Service
Dealer.

If for any reason you are dissatised with the Service Dealer’s analysis or with
the assistance provided, contact us at:

LCB Customer Service Department

Toro Warranty Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Owner Responsibilities

You must maintain your Toro Product by following the maintenance procedures
described in the operator’s manual. Such routine maintenance, whether
performed by a dealer or by you, is at your expense.

Items and Conditions Not Covered

There is no other express warranty except for special emission system coverage
on some products. This express warranty does not cover the following:

• Cost of regular maintenance service or parts, such as lters, fuel, lubricants,

tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required

replacement or repair due to normal wear, accidents, or lack of proper
maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or

failure to properly prepare the fuel system prior to any period of non-use
over three months.

• Pickup and delivery charges.

General Conditions

All repairs covered by this warranty must be performed by an Authorized Toro
Service Dealer using Toro approved replacement parts.

Neither The Toro® Company nor Toro Warranty Company is liable for
indirect, incidental or consequential damages in connection with the
use of the Toro Products covered by this warranty, including any
cost or expense of providing substitute equipment or service during
reasonable periods of malfunction or non-use pending completion
of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.

All implied warranties of merchantability (that the product is t
for ordinary use) and tness for use (that the product is t for
a particular purpose) are limited to the duration of the express
warranty.

This warranty gives you specic legal rights, and you may also have
other rights which vary from state to state.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee
policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information,
contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0037 Rev F