Toro TITAN HD 1500, TITAN HD 2000 Series, 74452, TITAN HD 2500 Series, 74461 Operator's Manual

FormNo.3405-604RevD

48in,52in,or60inTITAN
1500,2000,or2500SeriesRiding
Mower

ModelNo.74450—SerialNo.400010798andUp
ModelNo.74451—SerialNo.400010798andUp
ModelNo.74452—SerialNo.400010798andUp
ModelNo.74460—SerialNo.400010798andUp
ModelNo.74461—SerialNo.400010798andUp
ModelNo.74462—SerialNo.400010798andUp
ModelNo.74463—SerialNo.400010798andUp
ModelNo.74470—SerialNo.400010798andUp
ModelNo.74471—SerialNo.400010798andUp
ModelNo.74472—SerialNo.400010798andUp
ModelNo.78450—SerialNo.400010798andUp

®

HD

Registeratwww.T oro.com.
OriginalInstructions(EN)

*3405-604*D

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian
ICES-002

ItisaviolationofCaliforniaPublicResourceCode
Section4442or4443touseoroperatetheengineon
anyforest-covered,brush-covered,orgrass-covered
landunlesstheengineisequippedwithaspark
arrester,asdenedinSection4442,maintainedin
effectiveworkingorderortheengineisconstructed,
equipped,andmaintainedforthepreventionofre.

period,ensurethattheHighAltitudeKithasbeen
installedsothattheenginemeetsCARB/EP A
emissionregulations.TheHighAltitudeKit
increasesengineperformancewhilepreventing
spark-plugfouling,hardstarting,andincreased
emissions.Onceyouhaveinstalledthekit,attach
thehigh-altitudelabelnexttotheserialdecalon
themachine.ContactanyAuthorizedToroService
DealertoobtaintheproperHighAltitudeKitand
high-altitudelabelforyourmachine.Tolocate
adealerconvenienttoyou,accessourwebsite
atwww.T oro.comorcontactourToroCustomer
CareDepartmentatthenumber(s)listedinyour
EmissionControlWarrantyStatement.

Removethekitfromtheengineandrestorethe
enginetoitsoriginalfactorycongurationwhen
runningtheengineunder1500m(5,000ft).Do
notoperateanenginethathasbeenconverted
forhigh-altitudeuseatloweraltitudes;otherwise,
youcouldoverheatanddamagetheengine.

Ifyouareunsurewhetherornotyourmachinehas
beenconvertedforhigh-altitudeuse,lookforthe
followinglabel(Figure3).

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

GenuineT orosparkarrestersareapprovedbythe
USDAForestryService.

WARNING

Removingstandardoriginalequipmentparts
andaccessoriesmayalterthewarranty,
traction,andsafetyofthemachine.Failureto
useoriginalT oropartscouldcauseserious
injuryordeath.Makingunauthorizedchanges
totheengine,fuelorventingsystem,may
violateEPAandCARBregulations.

Replaceallpartsincluding,butnotlimited
to,tires,belts,blades,andfuelsystem
componentswithoriginalToroparts.

ForallmodelsthatdonothaveToroengines,
pleaserefertotheenginemanufacturer’s
informationincludedwiththemachine.

decal127-9363

Figure3

Labeledpowerratingsaresuppliedbytheengine
manufacturerinaccordancewithSAEtestingand
gross/netpowerratingstandards(J1940,J1995,
J1349).

Important:IfyouareusingamachinewithaToro

engineabove1500m(5,000ft)foracontinuous

©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA

AllRightsReserved

Introduction

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

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely .

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

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

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.

g000502

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Contents

Safety.......................................................................5

GeneralSafety...................................................5

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

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

ProductOverview...................................................14

Controls...........................................................14

Specications..................................................15

BeforeOperation.................................................16

BeforeOperationSafety...................................16

RecommendedFuel.........................................17

UsingStabilizer/Conditioner.............................17

FillingtheFuelTank..........................................17

CheckingtheEngine-OilLevel..........................17

UsingtheRollover-ProtectionSystem

(ROPS).........................................................18

ThinkSafetyFirst..............................................19

UsingtheSafety-InterlockSystem....................20

PositioningtheSeat..........................................20

ChangingtheSeatSuspension.........................20

BreakinginaNewMachine..............................21

g036742

UsingAttachmentsandAccessories.................21

DuringOperation.................................................21

DuringOperationSafety...................................21

OperatingtheParkingBrake.............................23

OperatingtheMowerBlade-ControlSwitch

(PTO)............................................................23

OperatingtheThrottle.......................................23

OperatingtheChoke.........................................24

OperatingtheIgnitionSwitch............................24

StartingtheEngine...........................................24

ShuttingOfftheEngine.....................................25

DrivingForwardorBackward............................26

AdjustingtheHeight-of-Cut...............................28

AdjustingtheAnti-ScalpRollers........................28

AdjustingtheSideBumpers..............................29

StoppingtheMachine.......................................29

UsingtheSideDischarge.................................30

OperatingTips.................................................30

AfterOperation....................................................31

AfterOperationSafety......................................31

UsingtheFuel-ShutoffValve.............................31

UsingtheDrive-Wheel-ReleaseValves............31

3

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

LoadingtheMachine........................................33

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

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

Pre-MaintenanceProcedures..............................37

MaintenanceandStorage.................................37

Lubrication..........................................................38

GreasingtheMachine.......................................38

LubricatingtheCaster-WheelHubs..................39

EngineMaintenance...........................................40

EngineSafety...................................................40

ServicingaKawasaki
ServicingaKohler

®

Engine..........................41

®

Engine...............................46

ServicingaT oroEngine....................................50

CheckingtheSparkArrester.............................55

ReplacingtheEmissions-AirIntake

Filter..............................................................55

FuelSystemMaintenance...................................55

ReplacingtheFuelFilter...................................55

ServicingtheFuelT ank.....................................56

ElectricalSystemMaintenance...........................56

ElectricalSystemSafety...................................56

ServicingtheBattery.........................................56

ServicingtheFuses..........................................58

DriveSystemMaintenance..................................59

CheckingtheSeatBelt.....................................59

CheckingtheRollover-Protection-System

(ROPS)Knobs..............................................59

AdjustingtheTracking......................................60

CheckingtheTirePressure...............................60

CheckingtheWheelLugNuts...........................60

CoolingSystemMaintenance..............................61

CleaningtheEngineScreen.............................61

BrakeMaintenance.............................................61

AdjustingtheParkingBrake..............................61

BeltMaintenance................................................63

InspectingtheBelts..........................................63

ReplacingtheMowerBeltforSideDischarge

MowerDecks................................................63

ReplacingtheMowerBeltforRearDischarge

MowerDecks................................................64

ReplacingtheHydraulicPump-Drive

Belt................................................................66

ControlsSystemMaintenance.............................67

AdjustingtheControl-HandlePosition..............67

AdjustingtheMotion-ControlLinkage...............67

HydraulicSystemMaintenance...........................69

HydraulicSystemSafety...................................69

ServicingtheHydraulicSystem........................69

ChangingtheHydraulic-SystemFiltersand

Fluid..............................................................70

MowerDeckMaintenance....................................72

LevelingtheMowerDeck..................................72

ServicingtheCuttingBlades.............................74

RemovingtheMowerDeck...............................78

ReplacingtheGrassDeector..........................78

Cleaning..............................................................79

CleaningundertheMower................................79

DisposingofWaste...........................................79

Storage...................................................................80

CleaningandStorage.......................................80

Troubleshooting......................................................81

Schematics.............................................................83

4

Safety

Thismachinehasbeendesignedinaccordancewith
ANSIB71.4-2012.

GeneralSafety

Thisproductiscapableofamputatinghandsand
feetandofthrowingobjects.Alwaysfollowallsafety
instructionstoavoidseriouspersonalinjury.

Usingthisproductforpurposesotherthanitsintended
usecouldprovedangeroustoyouandbystanders.

•Readandunderstandthecontentsofthis

Operator’sManualbeforeyoustarttheengine.
Ensurethateveryoneusingthisproductknows
howtouseitandunderstandsthewarnings.

•Donotputyourhandsorfeetnearmoving

componentsofthemachine.

•Donotoperatethemachinewithoutallguards

andothersafetyprotectivedevicesinplaceand
workingonthemachine.

•Keepclearofanydischargeopening.Keep

bystandersasafedistancefromthemachine.

•Keepchildrenoutoftheoperatingarea.Never

allowchildrentooperatethemachine.

•Stopthemachineandshutofftheenginebefore

servicing,fueling,oruncloggingthemachine.

Improperlyusingormaintainingthismachinecan
resultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafety-alertsymbol,whichmeans
Caution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeseinstructions
mayresultinpersonalinjuryordeath.

Youcanndadditionalitemsofsafetyinformationin
theirrespectivesectionsthroughoutthismanual.

5

SlopeIndicator

Figure4

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge

6

g011841

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal
machinemanufacturer.

93-7818

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

decaloemmarkt

decal93-7818

1.Warning—donottouchthehotsurface.

decal107-3069

decal106-5517

106-5517

1.Warning–thereisnorolloverprotectionwhentherollbaris
down.

2.Toavoidinjuryordeathfromarolloveraccident,keepthe
rollbarintheraisedandlockedpositionandweartheseat
belt.Lowertherollbaronlywhenabsolutelynecessary;do
notweartheseatbeltwhentherollbarisdown.

3.ReadtheOperator'sManual;driveslowlyandcarefully.

107-3069

decal109-6014

109-6014

7

109-6035

2500SeriesSideDischargeMachinesOnly

decal112-9028

112-9028

1.Warning—stayawayfrommovingparts;keepallguardsin
place.

decal109-6035

decal115-9625

115-9625

109-6036

RearDischargeMachinesOnly

1.ReadtheOperator’sManual.

2.Removetheignitionkeyandreadtheinstructionsbefore
servicingorperformingmaintenance.

3.Heightofcut

1.Parking

2.Parkingbrake—engaged

brake—disengaged

decal109-6036

decalhourmessagedisplay-116-5610

MessageDisplay

1.Hour4.Neutral

2.PTO5.Operator-presenceswitch

3.Parkingbrake6.Battery

112-3858

1500and2000SeriesSideDischargeMachinesOnly

1.ReadtheOperator's
Manual.

2.Readtheinstructions
beforeservicingor
performingmaintenance.

3.Removetheignitionkey
beforeadjustingtheheight
ofcut.

4.Height-of-cutsettings.

decal112-3858

8

116-8588

1.ReadtheOperator’sManual.

2.Rotatethedrivereleaseknobtoloosen,slidetheknob,
andtighten.

3.Pushthemachine.

decal117-3848

117-3848

1.Thrownobjecthazard—keepbystandersasafedistance
fromthemachine.

2.Thrownobjecthazard,mower—donotoperatethemachine
withoutdeector,dischargecover,orgrasscollection

decal116-8588

systeminplace.

3.Cutting/dismembermentofhandorfoot—stayawayfrom
movingparts;keepallguardsandshieldsinplace.

117-1194

1500and2000SeriesSide-DischargeMachinesOnly

1.Engine

117-2718

decal126-0768

126-0768

RearDischargeUnitsOnly

decal117-1 194

decal126-4363

126-4363

decal117-2718

1.Cutting/dismembermenthazard,fanandentanglement
hazard,belt.Shutofftheengineandremovekeybefore
adjusting,servicingorcleaning.

9

decal126-8161

126-8161

1.Heightofcut

1.ReadtheOperator’s

Manual.

2.Slideseatforward

decal126-4784

126-4784

1.ReadtheOperator’s
Manual

3.Pressdownonlatchto
unlockseat

4.Rotateseat

decal126-9939

126-9939

2.Filltobottomofllerneck;
warning–donotoverllthe
tank

1.Thrownobjectshazard

-keepbystandersa
safedistancefromthe
machine.

126-6599

RearDischargeUnits

2.Cutting/dismemberment
ofhand-stayawayfrom
movingparts;keepall
guardsandshieldsin
place.

decal127-0326

127-0326

decal126-6599

2500SeriesSideDischargeMachinesOnly

1.ReadtheOperator's
Manual.

2.Heightofcut

3.Removethekeyfrom
theignitionandreadthe
Operator'sManualbefore
performingmaintenance
orservicingthemachine.

10

127-6662

RearDischargeMowersOnly

decal131-1097

131-1097

ToroEnginesOnly

decal127-6662

1.Oildrain

1.Attention—readthe
Operator'sManual.

2.Removethenutbyturning
itclockwise.

3.Removetheboltbyturning
itcounterclockwise.

136-1305

1.Fast

2.Continuousvariablesetting5.Worklight(optional)

3.Slow

4.Choke

6.Powerpoint

11

decal136-1305

PTOSwitchSymbols

1.PTO–disengage2.PTO–engage

decalptosymbols

decalmotioncntrlrh-126-6183

RightMotionControl

TransportLock

1.Heightofcut

LeftMotionControl

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

2.Pulluptounlockthe
transportlock

decalmotioncntrllh-126-6194

decaltransportlock

1.Machinespeed4.Neutral

2.Fast5.Reverse

3.Slow

decalbatterysymbols

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

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

12

decal126-8151

126-8151

1.Readtheinstructionsbeforeservicingorperforming

4.RefertotheOperator'sManualforgreaseinstructions

maintenance

2.Timeinterval

5.Checkthehydraulic-uidlevelandrefertotheOperator's
Manualorfurtherinstructions

3.Checkoillevel6.Checktirepressure

126-8383

1.Warning-ReadtheOperator'sManual.Donotoperatethis
machineunlessyouaretrained.Wearhearingprotection.

2.Cuttingandpinchinghazard-keephandsandfeetawayfrom
movingparts;keepallguardsandshieldsinplace.

3.Ramphazard-whenloadingontoatrailer,donotusedual
ramps;onlyuseasingularrampwideenoughforthemachine
andthathasaninclinelessthan15degrees;backupthe
ramp(inreverse)anddriveforwardofftheramp.

4.Bodilyharmhazard-lookbehindyouwhenmowingin
reverse.

5.Thrownobjecthazard-keepbystandersaway .

6.Tippinghazardonslopes-donotuseonslopesnearopen
water;donotuseonslopesgreaterthan15degrees.

decal126-8383

13

ProductOverview

HourMeter

Thehourmeterrecordsthenumberofhoursthe
enginehasoperated.Itoperateswhentheengine
isrunning.Usethesetimesforschedulingregular
maintenance(Figure6).

ThrottleControl

ThethrottlecontrolisvariablebetweenFastand
Slow.

Choke

Usethechoketostartacoldengine.Pullthechoke
knobuptoengageit.

Figure5

1.Height-of-cutdeck-lift
pedal

2.Height-of-cutpositions

3.Transportlock9.Parking-brakelever

4.Controls

5.Motion-controllevers

6.Rollbar

7.Seatbelt

8.Fuelcap

10.Mowerdeck

11.Casterwheel

Controls

Becomefamiliarwithallthecontrolsbeforeyoustart
theengineandoperatethemachine(Figure5and

Figure6).

g036854

Blade-ControlSwitch(PTO)

Usetheblade-controlswitch(PTO)toengagethe
electricclutchanddrivethemowerblades.Pullthe
switchuptoengagethebladesandrelease.T o
disengagetheblades,pushtheblade-controlswitch
(PTO)downormoveamotion-controlleverintothe
NEUTRAL-LOCKposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas
3positions:START,RUN,andOFF.

Motion-ControlLevers

Themotion-controlleversareusedtodrivethe
machineforward,reverse,andturneitherdirection.

Neutral-LockPosition

UsetheNEUTRAL-LOCKpositionwiththe
safety-interlocksystemtoengageandtodetermine
theNEUTRALposition.

1.Powerpoint

2.Choke

3.Throttlecontrol

4.Hourmeter

Figure6

5.PTOSwitch

6.Ignitionswitch

7.Switchpositionforoptional
lightkit

g037119

Fuel-ShutoffValve

Closethefuel-shutoffvalve(undertheseat)when
transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsand
accessoriesisavailableforusewiththemachineto
enhanceandexpanditscapabilities.Contactyour
AuthorizedServiceDealerorDistributororgoto
www.T oro.comforalistofallapprovedattachments
andaccessories.

14

Specications

Note:Specicationsanddesignaresubjecttochangewithoutnotice.

Width—MachineswithSideDischargeMowerDecks

48-inchDeck52-inchDeck60-inchDeck

Withoutmowerdeck

Deectorup133cm(53inches)144cm(56-3/4inches)161cm(63-1/2inches)

Deectordown160cm(63-1/4inches)171cm(67-1/4inches)191cm(75-1/4inches)

Width—MachineswithRearDischargeMowerDecks

Withoutmowerdeck

Withmowerdeck

Length—MachineswithSideDischargeMowerDecks

Length

Length—MachineswithRearDischargeMowerDecks

121cm(47-1/2inches)124cm(49inches)133cm(52inches)

60-inchDeck

133cm(52inches)

168cm(66inches)

48-inchDeck52-inchDeck60-inchDeck

208cm(82inches)208cm(82inches)209cm(83inches)

60-inchDeck

Withmowerdeck

215cm(84-1/2inches)

Height

RollBar-UpRollBar-Down

179cm(70-1/2inches)49inches(125cm)

Weight

MachinesWeight

48-inchside-dischargemachines

52-inchside-dischargemachines

60-inchside-dischargemachines

60-inchrear-dischargemachines

385to425kg(849to937lb)

391to434kg(862to957lb)

409to456kg(901to1006lb)

459kg(1012lb)

15

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

BeforeOperation

BeforeOperationSafety

•Donotllcontainersinsideavehicleoronatruck

ortrailerbedwithaplasticliner.Alwaysplace
containersontheground,awayfromyourvehicle
beforelling.

•Removetheequipmentfromthetruckortrailer

andrefuelitwhileitisontheground.Ifthisisnot
possible,thenrefuelfromaportablecontainer
ratherthanafuel-dispensernozzle.

•Donotoperatethemachinewithouttheentire

exhaustsysteminplaceandinproperworking
condition.

GeneralSafety

•Neverallowchildrenoruntrainedpeopleto

operateorservicethemachine.Localregulations
mayrestricttheageoftheoperator.Theowner
isresponsiblefortrainingalloperatorsand
mechanics.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Knowhowtostopthemachineandenginequickly.

•Checkthatoperator-presencecontrols,safety

switches,andshieldsareattachedandfunctioning
properly.Donotoperatethemachineunlessthey
arefunctioningproperly.

•Beforemowing,alwaysinspectthemachineto

ensurethattheblades,bladebolts,andcutting
assembliesareingoodworkingcondition.
Replacewornordamagedbladesandboltsinsets
topreservebalance.

•Inspecttheareawhereyouwillusethemachine

andremoveallobjectsthatthemachinecould
throw.

•Evaluatetheterraintodeterminetheappropriate

equipmentandanyattachmentsoraccessories
requiredtooperatethemachineproperlyand
safely.

•Keepthefuel-dispensernozzleincontactwith

therimofthefueltankorcontaineropeningat
alltimesuntilfuelingiscomplete.Donotusea
nozzlelock-opendevice.

•Ifyouspillfuelonyourclothing,changeyour

clothingimmediately.Wipeupanygasolinethat
spills.

•Neveroverllthefueltank.Replacethefuelcap

andtightenitsecurely.

•Storegasolineinanapprovedcontainerandkeep

itoutofthereachofchildren.Neverbuymore
thana30-daysupplyofgasoline.

•Donotllthefueltankcompletelyfull.Add

gasolinetothefueltankuntilthelevelis6to13
mm(1/4to1/2inch)belowthebottomoftheller
neck.Thisemptyspaceinthetankallowsgasoline
toexpand.

–Avoidprolongedbreathingofvapors.

–Keepyourfaceawayfromthenozzleandgas

tankopening.

–Avoidcontactwithskin;washoffspillswith

soapandwater.

FuelSafety

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlingfuel.Fuelvaporsare
ammableandexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporaddfueltothefuel

tankwhiletheengineisrunningorwhilehot.

•Donotrefuelthemachineindoors.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such
asonawaterheateroronotherappliances.

16

RecommendedFuel

•Forbestresults,useonlyclean,fresh(lessthan

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

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl
ether)byvolumeisacceptable.Ethanoland
MTBEarenotthesame.Gasolinewith15%
ethanol(E15)byvolumeisnotapprovedforuse.

Neverusegasolinethatcontainsmorethan
10%ethanolbyvolume,suchasE15(contains

15%ethanol),E20(contains20%ethanol),orE85
(containsupto85%ethanol).Usingunapproved
gasolinemaycauseperformanceproblemsand/or
enginedamagewhichmaynotbecoveredunder
warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessafuelstabilizer
isused.

•Donotaddoiltogasoline.

4.Fillthefueltanktothebottomofthellerneck.

5.Ensurethatthereisemptyspaceinthetankto
allowthegasolinetoexpand(Figure7).

Using Stabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto
providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor

less.Forlongerstorageitisrecommendedthat
thefueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel

system,whichcauseshardstarting

Important:Donotusefueladditives

containingmethanolorethanol.

Addthecorrectamountofgasoline
stabilizer/conditionertothegasoline.

Note:Afuelstabilizer/conditionerismosteffective

whenmixedwithfreshgasoline.T ominimizethe
chanceofvarnishdepositsinthefuelsystem,use
fuelstabilizeratalltimes.

Figure7

CheckingtheEngine-Oil Level

Beforeyoustarttheengineandusethemachine,
checktheoillevelintheenginecrankcase.For
KawasakienginesrefertoServicingaKawasaki

Engine(page41),forKohlerenginesrefertoServicing
aKohler

refertoServicingaT oroEngine(page50).

®

Engine(page46),andforT oroengines

g036751

®

FillingtheFuelTank

Note:Donotllthefueltankcompletelyfull.Fillthe

fueltanktothebottomofthellerneck.Theempty
spaceinthetankallowsthegasolinetoexpand.

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefuel-tankcap.

17

Usingthe Rollover-ProtectionSystem (ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keep
therollbarinthefullyraised,lockedposition
andusetheseatbelt.

Ensurethattheseatissecuredtothe
machine.

WARNING

Thereisnorolloverprotectionwhentheroll
barisinthedownposition.

•Lowertherollbaronlywhenabsolutely
necessary.

•Donotweartheseatbeltwhentherollbar
isinthedownposition.

•Driveslowlyandcarefully.

g036746

Figure8

•Raisetherollbarassoonasclearance
permits.

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

Important:Ensurethattheseatissecuredto

themachine.

1.T olowertherollbar,applyforwardpressureto
theupperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90degrees
sotheyarenotengaged(Figure8).

3.Lowertherollbartothedownposition(Figure

8).

1.Rollbarintheupright
position

2.ROPSknobinthelatched
position

3.PulltheROPSknobout.6.Rollbarinthefolded

4.T oraisetherollbar,raisetherollbartothe

operatingpositionandrotatetheknobsuntil
theymovepartiallyintothegrooves(Figure8).

5.Raisetherollbartothefulluprightpositionwhile

pushingontheupperrollbarsothatthepins
snapintopositionwhentheholesalignwiththe
pins(Figure8).

6.Pushontherollbarandensurethatbothpins

areengaged.

4.RotatetheROPSknob90
degrees.

5.ROPSknobinthe
unlatchedposition

position

Important:Alwaysusetheseatbeltwiththeroll

barintheraisedposition.

18

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe
safetysection.Knowingthisinformationcouldhelp
youorbystandersavoidinjury.

DANGER

Operatingthemachineonwetgrassorsteep
slopescancauseslidingandlossofcontrol.

•Donotoperateonslopesgreaterthan15
degrees.

•Reducespeedanduseextremecautionon
slopes.

•Donotoperatethemachinenearwater.

DANGER

Wheelsdroppingoveredgescancause
rollovers,whichmayresultinseriousinjury,
death,ordrowning.

Donotoperatethemachineneardrop-offs.

1.SafeZone—usethe
machinehereonslopes
lessthan15degreesor
atareas.

2.DangerZone—usea
walk-behindmowerand/or
ahandtrimmeronslopes
greaterthan15degrees,
neardrop-offsandwater.

g000963

Figure9

3.Water

DANGER

Operatingthemachinewhiletherollbaris
downmayleadtoseriousinjuryordeathin
theeventofarollover.

Alwayskeeptherollbarinthefullyraisedand
lockedpositionandusetheseatbelt.

CAUTION

Thismachineproducessoundlevelsin
excessof85dBAattheoperator’searand
cancausehearinglossthroughextended
periodsofexposure.

Wearhearingprotectionwhenoperatingthis
machine.

Theuseofprotectiveequipmentforeyes,ears,
hands,feet,andheadisrecommended.

g009027

Figure10

1.Weareyeprotection.2.Wearhearingprotection

19

UsingtheSafety-Interlock System

Whiletheengineisrunning,releasetheparking
brake,engagetheblade-controlswitch(PTO),
andriseslightlyfromtheseat;theengineshould
shutoff.

CAUTION

Ifthesafety-interlockswitchesare
disconnectedordamaged,themachinecould
operateunexpectedly,causingpersonal
injury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock
switchesdailyandreplaceanydamaged
switchesbeforeoperatingthemachine.

Understandingthe
Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe
enginefromstartingunless:

•Theparkingbrakeisengaged.

•Theblade-controlswitch(PTO)isdisengaged.

•Themotion-controlleversareintheNEUTRAL-LOCK

position.

4.Sitontheseat,engagetheparkingbrake,
movetheblade-controlswitch(PTO)totheOFF
position,andmovethemotion-controllevers
toNEUTRAL-LOCKposition.Starttheengine.
Whiletheengineisrunning,centereither
motion-controlleverandmoveitforwardor
reverse;theengineshouldshutoff.Repeatfor
othermotion-controllever.

5.Sitontheseat,disengagetheparkingbrake,
movetheblade-controlswitch(PTO)totheOFF
position,andmovethemotion-controlleversto
NEUTRAL-LOCKposition.Trystartingtheengine;
theengineshouldnotcrank.

PositioningtheSeat

Theseatcanmoveforwardandbackward(Figure11).
Positiontheseatwhereyouhavethebestcontrolof
themachineandaremostcomfortable.

Thesafety-interlocksystemalsoisdesignedtoshutoff
theenginewhenyoumovethetractioncontrolsfrom
thelockedpositionwiththeparkingbrakeengagedor
ifyourisefromtheseatwhenthePTOisengaged.

TestingtheSafety-Interlock
System

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethe
machineeachtime.Ifthesafetysystemdoesnot
operateasdescribedbelow,haveanAuthorized
ServiceDealerrepairthesafetysystemimmediately .

1.Sitontheseat,engagetheparkingbrakeand
movetheblade-controlswitch(PTO)totheON
position.Trystartingtheengine;theengine
shouldnotcrank.

2.Sitontheseat,engagetheparkingbrakeand
movetheblade-controlswitch(PTO)totheOFF
position.Moveeithermotion-controllever(out
oftheNEUTRAL-LOCKposition).Trystartingthe
engine;theengineshouldnotcrank.Repeatfor
othercontrollever.

3.Sitontheseat,engagetheparkingbrake,
movetheblade-controlswitch(PTO)totheOFF
position,andmovethemotion-controlleversto
theNEUTRAL-LOCKposition.Starttheengine.

g028272

Figure11

ChangingtheSeat Suspension

Theseatisadjustabletoprovideasmoothand
comfortableride.Positiontheseatwhereyouare
mostcomfortable.

Toadjustit,turntheknobinfronteitherdirectionto
providethebestcomfort(Figure12).

20

Figure12

1.Seat-suspensionknob

BreakinginaNewMachine

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

UsingAttachmentsand Accessories

UseonlyToroapprovedattachmentsandaccessories.

Ifmorethanoneaccessory-mountkit(i.e.bucketkitor
universalmountkit)isaddedtoanyofthe4locations
showninFigure13,addafront-weightkit.Contact
yourauthorizedservicedealerforthefront-weightkit.

Figure13

1.Addafront-weightkitwhen2ormoreaccessory-mountkits

areinstalledatthesepositions.

DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible

foraccidentsthatmaycausepersonalinjuryor
propertydamage.

g024881

g037417

•Wearappropriateclothing,includingeye

protection;slip-resistant,substantialfootwear;and
hearingprotection.Tiebacklonghairanddonot
wearjewelry.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Nevercarrypassengersonthemachineandkeep

bystandersandpetsawayfromthemachine
duringoperation.

•Operatethemachineonlyingoodvisibilitytoavoid

holesorhiddenhazards.

•Avoidmowingonwetgrass.Reducedtraction

couldcausethemachinetoslide.

•Ensurethatalldrivesareinneutral,theparking

brakeisengaged,andyouareintheoperating
positionbeforeyoustarttheengine.

•Keepyourhandsandfeetawayfromthecutting

units.Keepclearofthedischargeopeningatall
times.

•Lookbehindanddownbeforebackinguptobe

sureofaclearpath.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscureyour
vision.

•Donotmowneardrop-offs,ditches,or

embankments.Themachinecouldsuddenlyroll
overifawheelgoesovertheedgeoriftheedge
givesway.

•Stopthebladeswheneveryouarenotmowing.

•Stopthemachineandinspectthebladesafter

strikinganobjectorifthereisanabnormal
vibrationinthemachine.Makeallnecessary
repairsbeforeresumingoperation.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalkswiththe
machine.Alwaysyieldtheright-of-way.

•Disengagethedrivetothecuttingunitandshut

offtheenginebeforeadjustingtheheightof
cut(unlessyoucanadjustitfromtheoperating
position).

•Neverrunanengineinanareawhereexhaust

gasesareenclosed.

•Neverleavearunningmachineunattended.

21

•Beforeleavingtheoperatingposition(including

toemptythecatchersortounclogthechute),do
thefollowing:

–Stopthemachineonlevelground.

–Disengagethepowertake-offandlowerthe

attachments.

–Settheparkingbrake.

–Shutofftheengineandremovethekey.

–Waitforallmovingpartstostop.

•Donotoperatethemachinewhenthereistherisk

oflightning.

•Donotusethemachineasatowingvehicle.

•Donotchangethegovernorspeedoroverspeed

theengine.

•Useaccessoriesandattachmentsapprovedby

Toroonly.

RolloverProtectionSystem
(ROPS)Safety

•DonotremovetheROPSfromthemachine.

•Ensurethattheseatbeltisattachedandthatyou

canreleaseitquicklyinanemergency.

•AlwayswearyourseatbeltwhentheROPSisup.

•Checkcarefullyforoverheadobstructionsanddo

notcontactthem.

•KeeptheROPSinsafeoperatingconditionby

thoroughlyinspectingitperiodicallyfordamage
andkeepingallthemountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairoralter

it.

•Choosealowgroundspeedsoyouwillnothave

tostoporshiftwhileonaslope.

•Arollovercanoccurbeforethetireslosetraction.

•Avoidoperatingthemachineonwetgrass.Tires

maylosetraction;regardlessifthebrakesare
availableandfunctioning.

•Avoidstarting,stopping,orturningthemachine

onaslope.

•Keepallmovementonslopesslowandgradual.

Donotsuddenlychangethespeedordirectionof
themachine.

•Donotoperatethemachineneardrop-offs,

ditches,embankments,orbodiesofwater.The
machinecouldsuddenlyrolloverifawheelgoes
overtheedgeortheedgecavesin.Establisha
safetyareabetweenthemachineandanyhazard
(2machinewidths).

SlopeSafety

•Establishyourownproceduresandrulesfor

operatingonslopes.Theseproceduresmust
includesurveyingthesitetodeterminewhich
slopesaresafeformachineoperation.Always
usecommonsenseandgoodjudgmentwhen
performingthissurvey.

•Slopesareamajorfactorrelatedtoloss-of-control

andtip-overaccidents,whichcanresultinsevere
injuryordeath.Operatingthemachineonany
sloperequiresextracaution.

•Operatethemachineatalowerspeedwhenyou

areonaslope.

•Ifyoufeeluneasyoperatingthemachineona

slope,donotdoit.

•Watchforholes,ruts,bumps,rocks,orother

hiddenobjects.Uneventerraincouldoverturnthe
machine.T allgrasscanhideobstacles.

22

OperatingtheParking Brake

Alwayssettheparkingbrakewhenyoustopthe
machineorleaveitunattended.

SettingtheParkingBrake

WARNING

Theparkingbrakemaynotholdamachine
parkedonaslopeandcouldcausepersonal
injuryorpropertydamage.

Donotparkthemachineonslopesunlessthe
wheelsarechockedorblocked.

EngagingtheBlade-Control
Switch(PTO)

Note:Engagingtheblade-controlswitch(PTO)with

thethrottlepositionathalforlesscausesexcessive
weartothedrivebelts.

g008945

Figure16

DisengagingtheBlade-Control
Switch(PTO)

Figure14

ReleasingtheParkingBrake

Figure15

OperatingtheMower Blade-ControlSwitch(PTO)

Theblade-controlswitch(PTO)startsandstopsthe
mowerbladesandanypoweredattachments.

g036754

g009174

Figure17

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweenFASTand
SLOWpositions(Figure18).

AlwaysusetheFASTpositionwhenturningonthe
mowerdeckwiththeblade-controlswitch(PTO).

g036755

g008946

Figure18

23

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostartthe
engine.

2.Pullupthechokeknobtoengagethechoke
beforeusingtheignitionswitch(Figure19).

3.Pushdownthechokeknobtodisengagethe
chokeafterstartingtheengine(Figure19).

g008947

Figure20

2.TurntheignitionkeytotheSTOPpositiontoshut
offtheengine.

StartingtheEngine

1.RaisetheROPSup,lockitintoplace,sitonthe
seat,andfastentheseatbelt.

2.MovethemotioncontrolstoNEUTRAL-LOCK
position.

3.Settheparkingbrake;refertoSettingthe

ParkingBrake(page23).

Figure19

1.ONposition2.OFFposition

OperatingtheIgnition Switch

1.TurntheignitionkeytotheST ARTposition
(Figure20).

Note:Whentheenginestarts,releasethekey.

Important:Donotengagethestarterfor

morethan5secondsatatime.Iftheengine
failstostart,wait15secondsbetween
attempts.Failuretofollowtheseinstructions
canburnoutthestartermotor.

4.Movetheblade-controlswitch(PTO)totheOFF
position(Figure17).

5.Movethethrottlelevermidwaybetweenthe

g008959

SLOWandFASTpositions.

Note:Y oumayneedmultipleattemptstostart

theenginewhenyoustartitthersttimeafter
thefuelsystemhasbeenwithoutfuelcompletely.

24

ShuttingOfftheEngine

Note:RefertoFigure40todeterminewhichengine

youhave.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

ShuttingOffKawasakiandKohler
Engines

Lettheengineidleatslowthrottlefor60seconds
beforeturningtheignitionswitchoff.

Figure21

6.TurntheignitionkeytotheST ARTposition
(Figure22).

Note:Whentheenginestarts,releasethekey.

Important:Donotengagestarterformore

than5secondsatatime.Iftheenginefails
tostart,allowa15secondcool-downperiod
betweenattempts.Failuretofollowthese
instructionscanburnoutthestartermotor.

Note:Youmayneedtoattempttostartthe

enginemultipletimeswhenyoustartitforthe
rsttimeafterthefuelsystemhasbeenwithout
fuelcompletely.

g036838

g036839

Figure23

Figure22

1.Off3.Start

2.Run

Important:Makesurethatthefuel-shutoff

g008947

valveisclosedbeforetransportingorstoring
themachine,asfuelleakagemayoccur.Setthe
parkingbrakebeforetransporting.Removethe
keyasthefuelpumpmayrunandcausethe
batterytolosecharge.

25

ShuttingOffToroEngines

Note:EnsurethethrottleisintheFASTposition

beforeshuttingofftheengine.

CAUTION

Machinecanspinveryrapidly.Youmaylose
controlofthemachineandinjureyourselfor
damagethemachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemaking
sharpturns.

UsingtheMotion-ControlLevers

Figure24

Important:Makesurethatthefuel-shutoff

valveisclosedbeforetransportingorstoring
themachine,asfuelleakagemayoccur.Setthe
parkingbrakebeforetransporting.Removethe
keyasthefuelpumpmayrunandcausethe
batterytolosecharge.

DrivingForwardor Backward

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

g037049

c:\data\documentum\checkout\g004532

Figure25

1.Motion-control
lever—NEUTRAL-LOCK
position

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

26

DrivingForward

DrivingBackward

Note:Theengineshutsoffifyoumovethe

traction-controlleverswiththeparkingbrakeengaged.

Tostopthemachine,pullthemotion-controllevers
totheNEUTRALposition.

1.Releasetheparkingbrake;refertoReleasing

theParkingBrake(page23).

2.Movetheleverstothecenter,unlockedposition.

3.T ogoforward,slowlypushthemotion-control
leversforward(Figure26).

1.Movetheleverstothecenter,unlockedposition.

2.T ogobackward,slowlypullthemotion-control
leversrearward(Figure27).

g008953

Figure27

Figure26

g008952

27

AdjustingtheHeight-of-Cut

UsingtheTransportLock

Thetransportlockhas2positions,andisusedwith
thedeck-liftpedal.ThereisaLOCKpositionand
anUNLOCKpositionforthetransportpositionofthe
mowerdeck(Figure28).

AdjustingtheHeight-of-CutPin

Adjusttheheight-of-cutfrom38to127mm(1-1/2to5
inches)in6mm(1/4inch)incrementsbymovingthe
height-of-cutpinintodifferentholelocations.

1.MovethetransportlocktotheLOCKposition.

2.Pushonthedeck-liftpedalwithyourfootand
raisethemowerdecktotheTRANSPORTposition
(alsothe127mmor5inchcutting-height
position)asshowninFigure29.

3.T oadjust,removethepinfromtheheight-of-cut
bracket(Figure29).

4.Selectaholeintheheight-of-cutbracket
correspondingtotheheight-of-cutdesired,and
insertthepin(Figure29).

5.Pushonthedecklift,pulluponthetransport
lockknob,andslowlylowerthemowerdeck.

Figure28

Transport-LockPositions

1.Transportlockknob3.UNLOCKposition—The

2.LOCKposition—The
mowerdecklocksintothe
transportposition.

mowerdeckdoesnotlock
intothetransportposition.

g036745

Figure29

1.Deck-liftpedal3.Height-of-cutpin

2.Height-of-cutholes

g037050

AdjustingtheAnti-Scalp

4.Transportlockknob

Rollers

Wheneveryouchangetheheight-of-cut,adjustthe
heightoftheanti-scalprollers.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

28

Figure30

2500seriesmowerdeckshown

1.Anti-scalproller4.Flangenut

2.Spacer

3.Bushing

5.Bolt

NEUTRAL-LOCKposition,applytheparkingbrake,
andremovethekey.

2.Shutofftheengine,removethekey,andwaitfor
allmovingpartstostop.

3.Raisethemowertothetransportposition.

4.Removetheboltsandnutsfromeachbumper
(Figure32).

g038079

g037862

Figure32

Figure31

1500and2000seriesmowerdeckshown

1.Flangenut4.Anti-scalproller

2.Bolt

3.Bushing

5.Spacer

AdjustingtheSideBumpers

(RearDischargeMachinesOnly)

Installthesidebumpersinthetopholeswhen
operatinginaheightofcuthigherthan64mm(2-1/2
inches)andinthecenterholeswhenoperatingina
heightofcutlowerthan64mm(2-1/2inches).

Note:Whenthebumpersbecomeworn,switchthe

bumperstotheoppositesidesofthemowerandip
themover.Thisallowsthebumperstobeusedlonger
beforereplacingthem.

1.Disengagetheblade-controlswitch(PTO),turn
theignitionkeytooff,movetheleverstothe

1.Bolt3.Nut

2.Bumper

5.Moveeachbumpertothedesiredpositionand
securethemwiththeboltsandnuts.

Note:Useonlythetoporcentersetsofholesto

adjustthebumpers.Usethebottomholeswhen

g036848

switchingsides,atwhichtimetheybecomethe
topholesontheothersideofthemower.

StoppingtheMachine

Tostopthemachine,movethemotion-controllevers
toneutralandthentotheNEUTRAL-LOCKposition,
disengagetheblade-controlswitch(PTO),andturn
theignitionkeytotheOFFposition.

Settheparkingbrakewhenyouleavethemachine;
refertoSettingtheParkingBrake(page23).Remove
thekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey
moveorattempttooperatethemachinewhile
itisunattended.

Alwaysremovetheignitionkeyandsetthe
parkingbrakewhenleavingthemachine
unattended,evenifjustforafewminutes.

29

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthat
dispersesclippingstothesideanddowntowardthe
turf.

DANGER

Withoutagrassdeector,dischargecover,or
acompletegrass-catcherassemblymounted
inplace,youandothersareexposedtoblade
contactandthrowndebris.Contactwith
rotatingmowerblade(s)andthrowndebris
causeinjuryordeath.

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

•Neverputyourhandsorfeetunderthe
mower.

•Nevertrytoclearthedischargearea
ormowerbladesunlessyoumovethe
blade-controlswitch(PTO)totheOFF
position,rotatetheignitionkeytotheOFF
position,andremovethekey.

•Makesurethatthegrassdeectorisinthe
downposition.

grassissparse,oritislatefallwhengrassgrows
moreslowly.

AlternatingtheMowingDirection

Alternatethemowingdirectiontokeepthegrass
standingstraight.Thisalsohelpsdisperseclippings
whichenhancesdecompositionandfertilization.

MowingatCorrectIntervals

Grassgrowsatdifferentratesatdifferenttimesof
theyear.T omaintainthesamecuttingheight,mow
moreofteninearlyspring.Asthegrassgrowthrate
slowsinmidsummer,mowlessfrequently.Ifyou
cannotmowforanextendedperiod,rstmowata
highcuttingheight,thenmowagain2dayslaterata
lowerheightsetting.

UsingaSlowerCuttingSpeed

Toimprovecutquality ,useaslowergroundspeed
incertainconditions.

AvoidingCuttingTooLow

Whenmowinguneventurf,raisethecuttingheight
toavoidscalpingtheturf.

StoppingtheMachine

OperatingTips

UsingtheFastThrottleSetting

Forbestmowingandmaximumaircirculation,operate
theengineattheFASTposition.Airisrequiredto
thoroughlycutgrassclippings,sodonotsetthe
height-of-cutsolowastototallysurroundthemower
inuncutgrass.Alwaystrytohave1sideofthemower
freefromuncutgrass,whichallowsairtobedrawn
intothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethat
thecuttingheightofthemowerdoesnotscalpany
unevenground.However,thecuttingheightusedin
thepastisgenerallythebestonetouse.Whencutting
grasslongerthan15cm(6inches)tall,youmaywant
tocutthelawntwicetoensureanacceptablequality
ofcut.

CuttingaThirdoftheGrassBlade

Itisbesttocutonlyaboutathirdofthegrassblade.
Cuttingmorethanthatisnotrecommendedunless

Ifyoumuststoptheforwardmotionofthemachine
whilemowing,aclumpofgrassclippingsmay
dropontoyourlawn.Toavoidthis,moveontoa
previouslycutareawiththebladesengagedoryou
candisengagethemowerdeckwhilemovingforward.

KeepingtheUndersideofthe
MowerClean

Cleanclippingsanddirtfromtheundersideofthe
moweraftereachuse.Ifgrassanddirtbuildupinside
themower,cuttingqualitywilleventuallybecome
unsatisfactory.

MaintainingtheBlade(s)

Maintainasharpbladethroughoutthecuttingseason
becauseasharpbladecutscleanlywithouttearingor
shreddingthegrassblades.Tearingandshredding
turnsgrassbrownattheedges,whichslowsgrowth
andincreasesthechanceofdisease.Checkthe
mowerbladesaftereachuseforsharpness,and
foranywearordamage.Filedownanynicksand
sharpenthebladesasnecessary.Ifabladeis
damagedorworn,replaceitimmediatelywitha
genuineT ororeplacementblade.

30

AfterOperation

AfterOperationSafety

GeneralSafety

•Cleangrassanddebrisfromthecuttingunits,

mufers,andenginecompartmenttohelpprevent
res.Cleanupoilorfuelspills.

•Shutoffthefuelbeforestoringortransportingthe

machine.

•Disengagethedrivetotheattachmentwhenever

youaretransportingornotusingthemachine.

•Usefull-widthrampsforloadingthemachineinto

atrailerortruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps
shouldbedirecteddownandoutwardfromthe
machine.

•Allowtheenginetocoolbeforestoringthemachine

inanyenclosure.

•Shutoffthefuelbeforestoringortransportingthe

machine.

•Neverstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such
asonawaterheateroronotherappliances.

g036849

g008948

Figure33

1.ONposition2.OFFposition

Usingthe
Drive-Wheel-Release

UsingtheFuel-Shutoff Valve

Thefuel-shutoffvalveislocatedbehindtheseat.

Closethefuel-shutoffvalvefortransport,maintenance,
andstorage.

Ensurethatthefuel-shutoffvalveisopenwhen
startingtheengine.

Valves

WARNING

Handsmaybecomeentangledintherotating
drivecomponentsbelowtheenginedeck,
whichcouldresultinseriousinjury.

Shutofftheengine,removethekey,andallow
allmovingpartstostopbeforeaccessingthe
drive-wheel-releasevalves.

WARNING

Theengineandhydraulic-driveunitscan
becomeveryhot.Touchingahotengineor
hydraulic-driveunitscancausesevereburns.

Allowtheengineandhydraulic-driveunits
tocoolcompletelybeforeaccessingthe
drive-wheel-releasevalves.

Thedrive-wheel-releasevalvesarelocatedontheleft
andrightsidesunderneaththeenginedeck.

1.Disengagetheblade-controlswitch(PTO),turn
theignitionkeytooff,movetheleverstothe

31

NEUTRAL-LOCKposition,applytheparkingbrake,
andremovethekey.

2.Locatethebypassleversbehindtheseat,down
ontheleftandrightsideoftheframe.

3.T opushthemachine,movebothbypassknobs
rearwardandlockthemintoplace(Figure34).

4.Disengagetheparkingbrakebeforepushing
themachine.

WARNING

Drivingonthestreetorroadwaywithout
turnsignals,lights,reectivemarkings,ora
slow-moving-vehicleemblemisdangerous
andcanleadtoaccidents,causingpersonal
injury.

Donotdrivethemachineonapublicstreet
orroadway.

1.Ifyouareusingatrailer,connectittothetowing
vehicleandconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Shutofftheengine,removethekey ,setthe
brake,andclosethefuelvalve.

5.Usethemetaltie-downloopsonthemachineto
securelyfastentheittothetrailerortruckwith
straps,chains,cable,orropes(Figure35).

Figure34

1.Frontofthemachine

2.Rotatebypassreleaseknobcounterclockwisetoloosen.

3.Leverpositionforoperatingthemachine

4.Pulltheleverinthisdirectiontopushthemachine.

5.Leverpositionforpushingthemachine

6.Rotatethebypass-releaseknobclockwisetotighten.

7.Engine

8.Releaselever

5.T orunthemachine,movethebypassknobsto
theFORWARDpositionandlockthemintoplace
(Figure34).

TransportingtheMachine

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

g035062

g036851

Figure35

1.Tie-downloops

32

LoadingtheMachine

WARNING

Useextremecautionwhenloadingorunloadingthe
machineontoatraileroratruck.Useafull-widthramp
thatiswiderthanthemachineforthisprocedure.
Backthemachineuptherampsanddriveitforward
downtheramps(Figure36).

Figure36

1.Backthemachineupthe

ramps.

2.Drivethemachineforward
downtheramps.

Important:Donotusenarrowindividualramps

foreachsideofthemachine.

Ensurethattherampislongenoughsothattheangle
withthegrounddoesnotexceed15degrees(Figure

37).Onatground,thisrequiresaramptobeatleast

4timesaslongastheheightofthetrailerortruckbed
totheground.Asteeperanglemaycausemower
componentstogetcaughtasthemachinemovesfrom
theramptothetrailerortruck.Steeperanglesmay
alsocausethemachinetotiporlosecontrol.Ifyou
areloadingthemachineonornearaslope,position
thetrailerortrucksothatitisonthedownsideof
theslopeandtherampextendsuptheslope.This
minimizestherampangle.

Loadingamachineontoatrailerortruck
increasesthepossibilityofatip-overand
couldcauseseriousinjuryordeath.

•Useextremecautionwhenoperatinga
machineonaramp.

•EnsurethattheROPSisintheupposition
andusetheseatbeltwhenloadingor
unloadingthemachine.Ensurethatthe
ROPSclearsthetopofanenclosedtrailer.

•Useonlyafull-widthramp;donotuse

g028043

individualrampsforeachsideofthe
machine.

•Donotexceeda15-degreeanglebetween
therampandthegroundorbetweenthe
rampandthetrailerortruck.

•Ensurethatthelengthoframpisatleast4
timesaslongastheheightofthetraileror
truckbedtotheground.Thisensuresthat
rampangledoesnotexceed15degreeson
atground.

•Backthemachineuptherampsanddrive
itforwarddowntheramps.

•Avoidsuddenaccelerationordeceleration
whiledrivingthemachineonarampasthis
couldcausealossofcontroloratip-over.

33

Figure37

g027996

1.Full-widthrampinstowed
position

2.Sideviewoffull-width
rampinloadingposition

3.Notgreaterthan
15degrees

4.Therampisatleast4
timesaslongastheheight
ofthetrailerortruckbed
totheground.

5.H=heightofthetraileror
truckbedtotheground

6.Trailer

34

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst5hours

Aftertherst75hours

Beforeeachuseordaily

Every25hours

Every50hours

MaintenanceProcedure

•ForToroengines—changetheengineoilandlter.

•Changethehydraulic-systemltersanduid.

•Checkthesafety-interlocksystem.

•ForKawasakiengines—checktheengine-oillevel.

•ForKohlerengines—checktheaircleanerfordirty,looseordamagedparts.

•ForKohlerengines—checktheengine-oillevel.

•Cleantheblowerhousing(moreoftenunderdusty,dirtyconditions).

•ForToroengines—checktheengine-oillevel.

•Checktheseatbelt.

•Checktherollover-protection-system(ROPS)knobs.

•Cleantheenginescreenandtheareaaroundtheengine.

•Cleanaroundtheengine-exhaustsystem.

•Checkthehydraulicuidlevelintheexpansiontank.

•Inspecttheblades.

•Cleanthemowerdeck.

•For1500and2000Seriesmachines—Greasethefrontcasteraxles.(moreoftenin
dirtyordustyconditions).

•ForKohlerengines—serviceorreplacetheair-cleanerfoamelement(moreoften
underdusty,dirtyconditions).

•ForToroengines—cleantheair-cleanerfoamelement(moreoftenindusty,dirty
conditions).

•For2500Seriesmachines—Greasethemowerdeck-idlerpivot.

•Greasethepump-idlerpivot.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

Every100hours

Every200hours

•ForKawasakiengines—changetheengineoil(moreoftenindirtyordusty
conditions).

•ForKawasakiengines—replaceorcleanandgapthesparkplug.

•ForKohlerengines—replacetheair-cleanerpaperelement(moreoftenunderdusty ,
dirtyconditions).

•ForKohlerengines—changetheengineoilandtheengine-oillter.

•ForKohlerengines—cleanthecoolingns(moreoftenunderdusty,dirtyconditions).

•ForToroengines—replacetheair-cleanerfoamelement(moreoftenindusty,
dirtyconditions).

•ForToroengines—servicetheair-cleanerpaperelement(moreoftenindusty ,
dirtyconditions).

•ForToroengines—changetheengineoilandoillter(moreoftenindusty,dirty
conditions).

•ForToroengines—checkthesparkplug(s).

•ForKawasakiengines—changetheengine-oillter(moreoftenindirtyordusty
conditions).

•ForKohlerengines—checkthesparkplug(s).

•ForToroengines—replacetheair-cleanerpaperelement(moreoftenindusty,
dirtyconditions).

•ForToroengines—replacethesparkplug(s).

35

MaintenanceService

Every250hours

Interval

MaintenanceProcedure

•ForKawasakiengines—replacetheprimaryairlter(moreoftenindustyorsandy
conditions).

•ForKawasakiengines—checkthesafetyairlter.

•Aftertheinitialchange—changethehydraulic-systemltersanduidwhenusing
Mobil115W50uid(changeitmoreoftenundersevereconditions).

Every300hours

Every500hours

Monthly

Yearly

Yearlyorbeforestorage

•ForKawasakiengines—Checkandadjustthevalveclearance.SeeanAuthorized
ServiceDealer.

•ForKawasakiengines—replacethesafetyairlter.

•ForKohlerengines—Checkandadjustthevalveclearance.SeeanAuthorized
ServiceDealer.

•ForKohlerengines—replacethesparkplug(s).

•Replacetheemissions-airintakelter.

•Replacethefuellter(moreoftenindusty,dirtyconditions).

•Checktheparkingbrakeadjustment.

•Aftertheinitialchange—changethehydraulic-systemltersanduidwhenusing
Toro®HYPR-OIL™500oil(changeitmoreoftenundersevereconditions).

•Checkthebatterycharge.

•For2500Seriesmachines—Lubricatethecaster-wheelhubs.

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand
seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

36

Pre-Maintenance
Procedures

MaintenanceandStorage

•Beforerepairingthemachinedothefollowing:

–Disengagethedrives.

–Settheparkingbrake.

–Shutofftheengineandremovethekey.

–Disconnectthespark-plugwire.

•Parkthemachineonalevelsurface.

•Cleangrassanddebrisfromthecuttingunit,drives,mufers,andenginetohelppreventres.

•Cleanupoilorfuelspills.

•Lettheenginecoolbeforestoringthemachine.

•Donotstorethemachineorfuelnearamesordrainthefuelindoors.

•Donotallowuntrainedpersonneltoservicethemachine.

•Usejackstandstosupportthemachineand/orcomponentswhenrequired.

•Carefullyreleasepressurefromcomponentswithstoredenergy.

•Disconnectthebatteryorremovethespark-plugwirebeforemakinganyrepairs.Disconnectthenegative

terminalrstandthepositiveterminallast.Connectthepositiveterminalrstandnegativelast.

•Usecarewhencheckingtheblades.Wraptheblade(s)orwearthicklypaddedgloves,andusecaution

whenservicingthem.Onlyreplaceblades;donotstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardwaretightened,especiallytheblade-attachmentbolts.

Replaceallwornordamageddecals.

•Neverinterferewiththeintendedfunctionofasafetydeviceorreducetheprotectionprovidedbyasafety

device.Checktheirproperoperationregularly.

•Toensureoptimumperformanceandcontinuedsafetycerticationofthemachine,useonlygenuineT oro

replacementpartsandaccessories.Replacementpartsandaccessoriesmadebyothermanufacturers
couldbedangerous,andsuchusecouldvoidtheproductwarranty.

•Checktheparkingbrakeoperationfrequently.Adjustandserviceasrequired.

37

Lubrication

GreasingtheMachine

Greasemorefrequentlywhenoperatingconditions
areextremelydustyorsandy.

GreaseType:No.2lithiumormolybdenumgrease

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Cleanthegreasettingswitharag.

Note:Makesuretoscrapeanypaintoffthe

frontofthetting(s).

4.Connectagreaseguntothetting,andpump
greaseintothettings.

5.Wipeupanyexcessgrease.

ServiceInterval:Every25hours—For1500and

2000Seriesmachines—Greasethe
frontcasteraxles.(moreoftenin
dirtyordustyconditions).

Every50hours—For2500Series
machines—Greasethemowerdeck-idler
pivot.

Every50hours—Greasethepump-idlerpivot.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Greasethemowerdeckandpumpidler-pulley
pivotwith1or2pumpsofgrease(Figure38).

4.For1500and2000Seriesmachines,greasethe
frontcasteraxles(Figure38).

Figure38

1.Pump-idlerpivot3.Mowerdeckidler-pulley

pivot(2500Series
machinesonly)

2.Casteraxle(1500and

2000Seriesmachines
only)

g037570

38

Lubricatingthe Caster-WheelHubs

2500SeriesMachinesOnly

ServiceInterval:Yearly—For2500Series

machines—Lubricatethe
caster-wheelhubs.

1.Shutofftheengine,waitforallmovingpartsto
stop,removethekey ,andengagetheparking
brake.

Figure39

1.Sealguard2.Spacernutwithwrench

ats

11.Withtheopenendofthewheelfacingup,ll
theareainsidethewheelaroundtheaxlefullof
general-purposegrease.

12.Insertthesecondbearingandnewsealintothe
wheel.

13.Applyathread-lockingcompoundtothesecond
spacernutandthreaditontotheaxlewiththe
wrenchatsfacingoutward.

14.T orquethenutto8to9N∙m(75to80in-lb),
loosenthenut,thentorqueitto2to3N∙m(20
to25in-lb).

Note:Makesurethattheaxledoesnotextend

beyondeithernut.

15.Installthesealguardsoverthewheelhuband
insertwheelintothecasterfork.

16.Installthecasterboltandtightenthenutfully.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoften.Spinthe

g006115

castertire.Thetireshouldnotspinfreely(more
than1or2revolutions)orhaveanysideplay.If
thewheelspinsfreely,adjustthetorqueonthe
spacernutuntilthereisaslightamountofdrag.
Applyanotherlayerofthread-lockingcompound.

2.Removethecasterwheelfromthecasterforks.

3.Removethesealguardsfromthewheelhub.

4.Removeaspacernutfromtheaxleassemblyin
thecasterwheel.

Note:Thread-lockingcompoundhasbeen

appliedtolockthespacernutstotheaxle.

5.Removetheaxle(withtheotherspacernutstill
assembledtoit)fromthewheelassembly.

6.Pryoutsealsandinspectbearingsforwearor
damageandreplaceifnecessary.

7.Packthebearingswithageneral-purpose
grease.

8.Insert1bearingand1newsealintothewheel.

Note:Replacetheseals.

9.Ifbothspacernutshavebeenremoved(or
brokenloose)fromtheaxleassembly,applya
thread-lockingcompoundto1spacernutand
threaditontotheaxlewiththewrenchats
facingoutward.

Note:Donotthreadthespacernutallof

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

10.Inserttheassemblednutandaxleintothewheel
onthesidewiththenewsealandbearing.

39

EngineMaintenance

Usethefollowinggraphictoidentifytheengineyouhaveandproceedtothesectionlistedbelowforservice
(Figure40).

Figure40

1.Kawasakiengine2.Kohlerengine3.Toroengine

g036852

•ForKawasakienginemaintenance,referto

ServicingaKawasaki

®

Engine(page41).

•ForKohlerenginemaintenance,refertoServicing

aKohler

®

Engine(page46).

•ForToroenginemaintenance,refertoServicinga

ToroEngine(page50).

WARNING

Contactwithhotsurfacesmaycausepersonalinjury.

Keepyourhands,feet,face,clothingandotherbodypartsawaythemuferandotherhot
surfaces.

EngineSafety

Shutofftheenginebeforecheckingtheoiloradding
oiltothecrankcase.

40

ServicingaKawasaki

®

Engine

ThissectionisonlyformachineswithKawasaki
engines.Ifyourenginelooksliketheoneshownin

Figure41,youhaveaKawasakiengine.

Important:Refertoyourenginemanufacturer’s

informationforadditionalmaintenance
procedures.

Figure41

g001883

Figure42

1.Air-cleanerbody4.Air-cleanercover

2.Primarylter5.Safetylter

3.Latch

4.Cleantheinsideoftheair-cleanercoverwith
compressedair.

5.Gentlyslidetheprimarylteroutofthe
air-cleanerbody(Figure42).

g036714

Note:Avoidknockingthelterintothesideof

thebody.

ServicingtheAirCleaner

ServiceInterval:Every250hours—ForKawasaki

engines—replacetheprimaryair
lter(moreoftenindustyorsandy
conditions).

Every250hours—ForKawasaki
engines—checkthesafetyairlter.

Every500hours—ForKawasaki
engines—replacethesafetyairlter.

Note:Checktheltersmorefrequentlyifthe

operatingconditionsareextremelydustyorsandy .

RemovingtheFilters

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Releasethelatchesontheaircleanerandpull
theair-cleanercoverofftheair-cleanerbody
(Figure42).

41

6.Removethesafetylteronlyifyouintendto
replaceit.

Important:Donotattempttocleanthe

safetylter.Ifthesafetylterisdirty,then
theprimarylterisdamaged.Replaceboth
lters.

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

Note:Holesinthelterappearasbrightspots.

Ifthelterisdamaged,discardit.

ServicingthePrimaryFilter

•Iftheprimarylterisdirty,bent,ordamaged,

replaceit.

•Donotcleantheprimarylter.

Viscosity:Seethetablebelow.

g037096

Figure43

ServicingtheSafetyFilter

Replacethesafetylter,nevercleanit.

Important:Donotattempttocleanthesafety

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

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandthe
coverinstalled.

1.Ifinstallingnewlters,checkeachlterfor
shippingdamage.

Note:Donotuseadamagedlter.

2.Ifyouarereplacingthesafetylter,carefully
slideitintothelterbody(Figure42).

3.Carefullyslidetheprimarylteroverthesafety
lter(Figure42).

Note:Ensurethattheprimarylterisfully

seatedbypushingonitsouterrimwhileinstalling
it.

Important:Donotpressonthesoftinside

areaofthelter.

4.Installtheair-cleanercoverwiththeside
indicatedasupfacingupwardandsecurethe
latches(Figure42).

ServicingtheEngineOil

Note:Although10W-40engineoilisrecommended

formostconditions,youmayneedtochangeoil
viscositytoaccommodateatmosphericconditions.
Using20W-50engineoilinhigherambient
temperaturescanreduceoilconsumption.

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal
injury.

Keephands,feet,face,clothing,andother
bodypartsawayfromthemuferandother
hotsurfaces.

Important:Donotoverllthecrankcasewithoil

becausethatcoulddamageengine.Donotrun
enginewithoilbelowtheLowmarkbecausethe
enginemaybedamaged.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition(Figure44).

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

CrankcaseCapacity:withalterchange,2.1L(71
oz);withoutalterchange,1.8L(61oz)

42

ChangingtheEngineOil

ServiceInterval:Every100hours(moreoftenindirty

ordustyconditions).

Note:Disposeoftheusedoilatarecyclingcenter.

1.Starttheengineandletitrunfor5minutes.

g036856

2.Parkthemachinesothattherearisslightly
lowerthanthefronttoensurethattheoildrains
completely.

3.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

4.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition(Figure45).

g036856

Note:Thiswarmstheoilsothatitdrainsbetter.

Figure44

g225269

g225280

Figure45

43

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

46).

ChangingtheEngine-OilFilter

ServiceInterval:Every200hours—ForKawasaki

engines—changetheengine-oil
lter(moreoftenindirtyordusty
conditions).

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page43).

2.Changetheengine-oillter(Figure47).

g036856

Figure46

6.Starttheengineanddrivetoaatarea.

7.Checktheoillevelagain.

g027660

g027477

Figure47

Note:Ensurethattheoil-ltergaskettouches

theengine,andthenturntheoillteranextra
3/4turn.

3.Fillthecrankcasewiththepropertypeofnew
oil;refertoServicingtheEngineOil(page42).

44

ServicingtheSparkPlug

CheckingtheSparkPlug

ServiceInterval:Every100hours

Makesurethattheairgapbetweenthecenterand
sideelectrodesiscorrectbeforeinstallingthespark
plug.Useasparkplugwrenchforremovingand
installingthesparkplug(s)andagappingtool/feeler
gaugetocheckandadjusttheairgap.Installanew
sparkplug(s)ifnecessary.

TypeofSparkPlug:NGK

®

BPR4ESorequivalent

AirGap:0.76mm(0.03inch)

RemovingtheSparkPlug

1.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

2.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

3.Locateandremovethesparkplugs(Figure48).

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithas:a
blackcoating,wornelectrodes,anoilylm,or
cracks.

Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly.Ablackcoatingonthe
insulatorusuallymeanstheaircleanerisdirty .

Setthegapto0.76mm(0.03inch).

g027479

Figure49

InstallingtheSparkPlug

Figure48

Tightenthesparkplug(s)to22N∙m(16ft-lb).

g036857

g027478

g027735

Figure50

45

ServicingaKohler

ThissectionisonlyformachineswithKohlerengines.
IfyourenginelooksliketheoneshowninFigure51,
youhaveaKohlerengine.

®

Engine

Important:Refertoyourenginemanufacturer’s

informationforadditionalmaintenance
procedures.

Figure51

2.Removethecovertoaccesstheair-cleaner
elements(Figure52).

g028105

Figure52

1.Air-cleanercover2.Air-cleanerlatch

3.Removethefoamandpaperelements(Figure

g036713

53).

4.Removethefoamelementfromthepaper
element(Figure53).

ServicingtheAirCleaner

ServiceInterval:Beforeeachuseordaily—For

Kohlerengines—checktheair
cleanerfordirty ,looseordamaged
parts.

Every25hours—ForKohlerengines—service
orreplacetheair-cleanerfoamelement(more
oftenunderdusty ,dirtyconditions).

Every100hours—ForKohlerengines—replace
theair-cleanerpaperelement(moreoftenunder
dusty,dirtyconditions).

Thisengineisequippedwithareplaceable,
high-densitypaperandfoamair-cleanerelement.
Checktheaircleanerdailyorbeforestartingthe
engine.Checkforabuildupofdirtanddebrisaround
theair-cleanersystem.Keepthisareaclean.Also,
checkforlooseordamagedcomponents.Replaceall
bentordamagedair-cleanercomponents.

Note:Operatingtheenginewithlooseordamaged

air-cleanercomponentscouldallowunlteredairinto
theengine,causingprematurewearandfailure.

g028106

Figure53

1.Air-cleanercover3.Paperelement

2.Foamelement

ServicingtheFoamElement

1.Washthefoamelementinwarmwaterand
detergent.

2.Rinseandallowittoairdry.

3.Lightlyoilthefoamelementwithnewoiland
squeezeoutexcessoil.

Note:Servicetheaircleanermoreoftenunderdusty,

dirtyconditions.

RemovingtheElements

1.Rotatethelatchesoutward.

ServicingthePaperElement

1.Gentlytapthepaperelementtodislodgedirt.

Note:Donotwashthepaperelementoruse

pressurizedair,asthiswilldamagetheelement.

46

Note:Replaceadirty,bent,ordamaged

element.Handlethenewelementcarefully;
donotuseifthesealingsurfacesarebentor
damaged.

2.Cleantheair-cleanerbaseasrequired,and
checkthecondition.

InstallingtheElements

1.Installthefoamelementontothepaperelement.

2.Installtheelementsontotheair-cleanerbase
(Figure53).

3.Installthecover,andsecureitwiththelatches
(Figure52).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSJorhigher)

CrankcaseCapacity:1.9L(64oz)whenthelter

ischanged

Viscosity:Seethetablebelow.

Figure54

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily

1.Parkthemachineonalevelsurface,disengage
theblade-controlswitch,shutofftheengine,
andremovethekey.

2.Makesurethattheengineisshutoff,level,and
iscool,sotheoilhastimetodrainintothesump.

3.Checktheengine-oillevel(Figure55).

g027515

Figure55

ChangingtheEngineOilandtheEngine-Oil
Filter

ServiceInterval:Every100hours—ForKohler

engines—changetheengineoiland
theengine-oillter.

g017552

Note:Thedrainplugisattachedtothedrainhose.

Note:Disposeoftheusedoilatarecyclingcenter.

Fillwithoilasspeciedinthe“ViscosityGrades”table
(Figure54).

1.Parkthemachine,sothatthedrainsideis
slightlylowerthantheoppositeside,toensure
thattheoildrainscompletely.

2.Disengagetheblade-controlswitchandmove
themotioncontrolsoutwardtothePARKposition.

3.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

47

Figure56

g027934

4.T orquetheplugto14N∙m(10ft-lb).

5.Changetheengine-oillterasshowninFigure

57.

g038074

Figure57

6.Slowlypourapproximately80%ofthespecied
oilintothellertube(Figure58).

48

Figure58

ServicingtheSparkPlug

ServiceInterval:Every200hours—ForKohler

engines—checkthesparkplug(s).

Every500hours—ForKohlerengines—replace
thesparkplug(s).

g027478

Figure59

CheckingtheSparkPlug

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithas:a
blackcoating,wornelectrodes,anoilylm,or
cracks.

Note:Ifyouseelightbrownorgrayontheinsulator,

theengineisoperatingproperly.Ablackcoatingon
theinsulatorusuallymeanstheaircleanerisdirty.

Setthegapto0.76mm(0.03inch).

g027517

g027479

Figure60

ThesparkplugisRFIcompliant.Equivalentalternate
brandplugscanalsobeused.

Type:ChampionXC12YC

AirGap:0.76mm(0.03inch)

RemovingtheSparkPlug

1.Disengagetheblade-controlswitch,movethe
motioncontrolsoutwardtotheparkposition,
shutofftheengine,andremovethekey .

2.Beforeremovingthesparkplug(s),cleanthe
areaaroundthebaseoftheplugtokeepdirt
anddebrisoutoftheengine.

3.Removethesparkplug(Figure59).

49

InstallingtheSparkPlug

Tightenthesparkplugto27N∙m(20ft-lb)asshown
inFigure61.

Figure61

ServicingaToroEngine

ThissectionisonlyformachineswithToroengines.
IfyourenginelookslikewhatisshowninFigure62,
youhaveaT oroengine.

g036715

Figure62

g028109

ServicingtheAirCleaner

CleaningtheBlowerHousing

Every100hours/Y early(whichevercomes
rst)—ForKohlerengines—cleanthecooling
ns(moreoftenunderdusty,dirtyconditions).

Toensurepropercooling,ensurethatthegrass
screen,coolingns,andotherexternalsurfacesofthe
enginearekeptcleanatalltimes.

ForKohlerengines,removetheblowerhousing,and
anyothercoolingshrouds.Cleanthecoolingnsand
externalsurfacesasnecessary.Makesurethatthe
coolingshroudsareinstalled.

Important:Operatingtheenginewithablocked

grassscreen,dirtyorpluggedcoolingns,and/or
coolingshroudsremoved,willcauseengine
damageduetooverheating.

ServiceInterval:Every25hours/Monthly

(whichevercomesrst)—For
Toroengines—cleantheair-cleaner
foamelement(moreoftenindusty,
dirtyconditions).

Every100hours/Y early(whichevercomes
rst)—ForToroengines—replacethe
air-cleanerfoamelement(moreoftenindusty,
dirtyconditions).

Every100hours/Y early(whichevercomes
rst)—ForToroengines—servicetheair-cleaner
paperelement(moreoftenindusty,dirty
conditions).

Every200hours/Every2years(whichever
comesrst)—ForT oroengines—replacethe
air-cleanerpaperelement(moreoftenindusty,
dirtyconditions).

RemovingtheElements

1.Parkthemachineonalevelsurfaceand
disengagetheblade-controlswitch(PTO).

2.Engagetheparkingbrake,shutofftheengine,
removethekey,andwaitforallmovingpartsto
stopbeforeleavingtheoperatingposition.

3.Cleanaroundtheair-cleanercovertoprevent
dirtfromgettingintotheengineandcausing
damage.

4.Liftthecoverandrotatetheair-cleanerassembly
outoftheengine(Figure63).

50

Important:Donotcleanthepaperelement

withpressurizedairorliquids,suchas
solvent,gas,orkerosene.Replacethepaper
elementifitisdamagedorcannotbecleaned
thoroughly.

ServicingtheEngineOil

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

orSL)

Figure63

5.Removethefoamelementfromthepaper
element(Figure64).

g027800

CrankcaseCapacity:2.4L(80oz)withoillter

Viscosity:Seethetablebelow.

g029683

Figure65

g027801

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily—ForT oro

engines—checktheengine-oillevel.

Note:Checktheoilwhentheengineiscold.

Figure64

ServicingtheFoamElement

Washthefoamelementwithwaterandreplaceitif
itisdamaged.

ServicingthePaperElement

1.Lightlytaptheelementonaatsurfaceto
removedustanddirt.

2.Inspecttheelementfortears,anoilylm,and
damagetotheseal.

WARNING

Contactwithhotsurfacesmaycausepersonal
injury.

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

g027802

surfaces.

Important:Donotoverllthecrankcasewithoil,

becausedamagetotheenginemayresult.Donot
runenginewithoilbelowtheLowmark,because
theenginemaybedamaged.

1.Parkthemachineonalevelsurface,disengage
theblade-controlswitch,shutofftheengine,
engagetheparkingbrake,andremovethekey.

2.Makesurethattheengineisshutoff,level,and
iscoolsothattheoilhashadtimetodraininto
thesump.

3.T okeepdirt,grassclippings,etc.,outofthe
engine,cleantheareaaroundtheoil-llcapand
dipstickbeforeremovingit(Figure66).

51

Figure66

g027799

g029368

ChangingtheEngineOilandOilFilter

ServiceInterval:Aftertherst5hours/Aftertherst

month(whichevercomesrst)—For
Toroengines—changetheengine
oilandlter.

Every100hours/Y early(whichevercomes
rst)—ForT oroengines—changetheengine
oilandoillter(moreoftenindusty,dirty
conditions).

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachineonalevelsurfacetoensure
theoildrainscompletely.

2.DisengagethePTOandengagetheparking
brake.

3.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

4.Draintheengineoil(Figure67).

g029570

Figure67

52

5.Changetheengine-oillter(Figure68).

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

69).

Figure68

Note:Ensurethattheoil-ltergaskettouches

theengineandthenturnthelteranextra3/4
turn.

g027484

Figure69

g027477

ServicingtheSparkPlug

ServiceInterval:Every100hours/Yearly

(whichevercomesrst)—For
Toroengines—checkthespark
plug(s).

Every200hours/Every2years(whichever
comesrst)—ForT oroengines—replacethe
sparkplug(s).

Makesurethattheairgapbetweenthecenterand
sideelectrodesiscorrectbeforeinstallingthespark
plug.Useaspark-plugwrenchtoremoveandinstall
thesparkplug(s)andagappingtool/feelergaugeto
checkandadjusttheairgap.Installanewspark
plug(s)ifnecessary.

Type:ChampionRN9YCorNGKBPR6ES

Airgap:0.76mm(0.03inch)

53

RemovingtheSparkPlug

InstallingtheSparkPlug

1.DisengagethePTOandengagetheparking
brake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

Figure70

Note:Duetothedeeprecessaroundthespark

plug,blowingoutthecavitywithcompressedair
isusuallythemosteffectivemethodforcleaning.
Thesparkplugismostaccessiblewhenthe
blowerhousingisremovedforcleaning.

CheckingtheSparkPlug

Tightenthesparkplug(s)to25to30N∙m(19to22
ft-lb).

g027478

g027735

Figure72

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithas:a
blackcoating,wornelectrodes,anoilylm,or
cracks.

Ifyouseelightbrownorgrayontheinsulator,the
engineisoperatingproperly.Ablackcoatingonthe
insulatorusuallymeanstheaircleanerisdirty .

Setthegapto0.76mm(0.030inch).

Figure71

CleaningtheCoolingSystem

Cleantheair-intakescreenfromgrassanddebris
beforeeachuse.

1.Disengagetheblade-controlswitchandengage
theparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Removetheairlterfromtheengine.

4.Removetheengineshroud.

5.T opreventdebrisenteringtheairintake,install
theairltertothelterbase.

6.Cleandebrisandgrassfromtheparts.

g027479

7.Removetheairlterandinstalltheengine
shroud.

8.Installtheairlter.

54

CheckingtheSpark

FuelSystem

Arrester

ForMachineswithaSpark
Arrester

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite
gasolinevaporsevenafteryoushutoffthe
engine.Hotparticlesexhaustedduringengine
operationmayigniteammablematerials.
Firemayresultinpersonalinjuryorproperty
damage.

Donotrefuelorruntheengineunlessaspark
arresterisinstalled.

1.Shutofftheengine,waitforallmovingpartsto
stop,andremovekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifthereareanybreaksinthescreenorwelds,
replacethearrester.

4.Ifthescreenisplugged,removethearrester
andshakethelooseparticlesoutofthearrester
andcleanthescreenwithawirebrush(soakit
insolventifnecessary).Installthearresteron
theexhaustoutlet.

Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every500hours/Yearly(whichever

comesrst)(moreoftenindusty,
dirtyconditions).

Important:Installthefuellinehosesandsecure

withplastictiesthesameastheywereoriginally
installedatthefactorytokeepthefuellineaway
fromcomponentsthatcancausefuellinedamage.

Thefuellterislocatedneartheengineontheleft
frontoftheengine.

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Allowthemachinetocooldown.

4.Closethefuel-shutoffvalveundertheseat
(Figure33).

Replacingthe Emissions-AirIntakeFilter

ServiceInterval:Every500hours

1.Shutofftheengine,waitforallmovingpartsto
stop,andremovekey.Engageparkingbrake.

2.Removethelterfromtheventhose.

3.Insertanewlterintotheendoftheventhose.

55

Figure73

Kohlerengineltershown

ElectricalSystem
Maintenance

ElectricalSystemSafety

•Disconnectthebatterybeforerepairingthe

machine.Disconnectthenegativeterminalrst
andthepositivelast.Connectthepositiveterminal
rstandthenegativelast.

•Chargethebatteryinanopen,well-ventilated

area,awayfromsparksandames.Unplugthe
chargerbeforeconnectingordisconnectingthe
battery.Wearprotectiveclothinganduseinsulated
tools.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

g029685

handsafterhandling.

5.Openthefuel-shutoffvalve.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan
AuthorizedServiceDealerdrainsthefueltankand
servicesanycomponentsofthefuelsystem.

ServicingtheBattery

ServiceInterval:Monthly

DANGER

Batteryelectrolytecontainssulfuricacid,
whichisadeadlypoisonandcausessevere
burns.

Donotdrinkelectrolyteandavoidcontact
withskin,eyes,orclothing.Wearsafety
glassestoshieldyoureyesandwearrubber
glovestoprotectyourhands.

56

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponents,causing
sparks.Sparkscancausethebatterygasses
toexplode,resultinginpersonalinjury.

•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthemachine.

•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.

WARNING

Incorrectbatterycableroutingcoulddamage
themachineandcables,causingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.

g036853

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

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

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Disconnectthenegativebatterycable(black)
fromthenegative(-)batteryterminal(Figure74).

4.Slidetheredterminalbootoffthepositive(red)
batteryterminal,andremovethepositive(+)
batterycable(Figure74).

5.Removetherubberstrap(Figure74).

6.Removethebattery.

g036855

Figure74

57

InstallingtheBattery

1.Positionthebatteryinthetraywiththeterminal
postsoppositefromthehydraulictank(Figure

74).

2.Installthepositive(red)batterycabletothe
positive(+)batteryterminal.

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

4.Securethecableswith2bolts,2washers,and
2locknuts(Figure74).

5.Slidetheredterminalbootontothepositive(+)
batteryterminal.

6.Securethebatterywiththerubberstrap(Figure

74).

ChargingtheBattery

1.Positivebatterypost

2.Negativebatterypost

g000960

Figure75

3.Red(+)chargerlead

4.Black(-)chargerlead

WARNING

Chargingthebatteryproducesgassesthat
canexplode.

Neversmokenearthebatteryandkeepsparks
andamesawayfromthebattery.

Important:Alwayskeepthebatteryfullycharged

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

1.Chargebatteryfor10to15minutesat25to30
Aorfor30minutesat10A.

2.Whenthebatteryisfullycharged,unplug
thechargerfromtheelectricaloutlet,then
disconnectthechargerleadsfromthebattery
posts(Figure75).

3.Installthebatteryinthemachineandconnect
thebatterycables;refertoInstallingtheBattery

(page58).

Note:Donotrunthemachinewiththebattery

disconnected;electricaldamagemayoccur.

ServicingtheFuses

Theelectricalsystemisprotectedbyfuses.Itrequires
nomaintenance,however,ifafuseblowscheckthe
componentandcircuitforamalfunctionorshort.

Thefusesarelocatedontherightconsolenexttothe
seat(Figure76).

1.T oreplacethefuses,pulloutthefusetoremove
it.

2.Installanewfuse(Figure76).

g036858

Figure76

1.Fusecover

2.Fuseholder

58

3.Fuel-shutoffvalve

DriveSystem
Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Inspecttheseatbeltforwear,cuts,andproper
operationoftheretractorandbuckle.Replacethe
seatbeltifitisdamaged.

Checkingthe Rollover-Protection-System (ROPS)Knobs

ServiceInterval:Beforeeachuseordaily

WARNING

Toavoidinjuryordeathfromrollover,keep
therollbarinthefullyraised,lockedposition
andusetheseatbelt.

Ensurethattheseatissecuredtothe
machine.

•Checkthatboththemountinghardwareandthe

knobsareingoodworkingcondition.

•Makesurethattheknobsarefullyengagedwith

theROPSintheraisedposition.

1.Rollbarintheupright

position

2.ROPSknobinthelatched

position

3.PulltheROPSknobout

androtateit90degrees.

g036746

Figure77

4.RotatetheROPSknob90
degrees.

5.ROPSknobinthe
unlatchedposition

6.Rollbarinthefolded
position

Note:Theupperhoopoftherollbarmayneed

tobepushedforwardorpulledrearwardtofully
engagebothknobs(Figure77andFigure78).

g034593

Figure78

1.Engaged2.Partiallyengaged—donot
operatewiththeROPSin
thisposition.

59

AdjustingtheTracking

CheckingtheTirePressure

1.Disengagetheblade-controlswitch(PTO).

2.Drivetoanopen,atareaandmovethe
motion-controlleverstotheNEUTRAL-LOCK
position.

3.MovethethrottlemidwaybetweentheFASTand
SLOWpositions.

4.Movebothmotion-controlleversforwarduntil
theybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifthemachinetrackstotheright,inserta
3/16-inchhexwrenchthroughtheaccessholein
therightfrontcoverpanelandrotatethetracking
screwclockwiseorcounterclockwisetoadjust
thetravelofthelever(Figure79).

7.Ifthemachinetrackstotheleft,inserta
3/16-inchhexwrenchthroughtheaccessholein
therightfrontcoverpanelandrotatethetracking
screwclockwiseorcounterclockwisetoadjust
thetravelofthelever(Figure79).

8.Drivethemachineandcheckthefullforward
tracking.

9.Repeattheadjustmentuntilthedesiredtracking
isobtained.

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthefrontandreartires
at90kPa(13psi).Uneventirepressurecancause
unevencut.Checkthetireswhentheyarecoldtoget
themostaccuratepressurereading.

g001055

Figure80

CheckingtheWheelLug Nuts

1.Accessholeonfrontcover

panel

Checkandtorquethewheellugnutsto122to136
N∙m(90to100ft-lb).

g035859

Figure79

Leftcontrollevershown

2.Trackingscrew

60

CoolingSystem
Maintenance

BrakeMaintenance

AdjustingtheParking

CleaningtheEngineScreen

ServiceInterval:Beforeeachuseordaily

Beforeeachuseordaily

Beforeeachuseremoveanybuildupofgrass,dirt,or
otherdebrisfromtheenginescreen,engineexhaust,
andtheareaaroundtheengine.Thishelpsensure
adequatecoolingandcorrectenginespeedand
reducesthepossibilityofoverheatingandmechanical
damagetotheengine.

Brake

ServiceInterval:Every500hours

Note:Makesuretofollowthisprocedurewhena

brakecomponenthasbeenremovedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

3.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

4.Setupthemachinetobepushedbyhand.Refer
toUsingtheDrive-Wheel-ReleaseValves(page

31).

5.Raisethebackofthemachineupandsupport
themachinewithjackstands.

CAUTION

Raisingthemachineforservice
ormaintenancerelyingsolelyon
mechanicalorhydraulicjackscouldbe
dangerous.Themechanicalorhydraulic
jacksmaynotbeenoughsupportormay
malfunctionallowingthemachinetofall,
whichcouldcauseinjury .

Donotrelysolelyonmechanical
orhydraulicjacksforsupport.Use
adequatejackstandsorequivalent
support.

6.Engageanddisengagetheparkingbrakeand
checkeachdrivetiretoensurethateachbrake
engagesanddisengages.

7.Ifanadjustmentisnecessary ,disengagethe
parkingbrake.Removethecotterpinfromthe
brakelinkageshaft(Figure81).

61

Figure81

1.Cotterpin3.Brakelinkageshaft

2.Parkingbrake

8.CheckbothspringlengthsasshowninFigure

82.Ifanadjustmentisnecessary,turnthe

topnutclockwisetoshortenthespringand
counterclockwisetolengthenit.

10.Rotatethebrake-linkageshaftuntiltheend
alignswiththeholeinthelever.

•Shortenthelinkagebyturningitclockwise.

•Lengthenthelinkagebyturningit

counterclockwise.

11.Insertthebrake-linkageshaftintothe
parking-brakeholeandsecurewiththecotter
pin.Repeatstep6andadjustifnecessary.

12.Whenadjustmentiscomplete,removethejack
standsorequivalentsupportandlowerthe
machine.

13.PlacethemachineintotheOPERATINGposition.

g036752

RefertoUsingtheDrive-Wheel-ReleaseValves

(page31).

Figure82

1.Topnut

2.Spring

3.44mm(1-3/4inches)

9.Pushtheparkingbrakeleverallthewayforward
anddown.

g036100

62

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours

Replacethebeltifitisworn.Thesignsofawornbelt
includesquealingwhilethebeltisrotating;theblades
slippingwhilecuttinggrass;andfrayededges,burn
marks,andcracksonthebelt.

ReplacingtheMowerBelt forSideDischargeMower Decks

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Lowerthemowertothe76mm(3inch)
height-of-cut.

4.Removethebeltcovers(Figure83).

Figure84

1500and2000SeriesMowerDecks

1.Clutchpulley3.Spring-loadedidlerpulley

2.Mowerbelt

4.Spring

g036861

Figure83

5.Removethespringtensionfromthe
spring-loadedidlerpulley.RefertoFigure84
orFigure86.

Note:For1500and2000Seriesmower

decks,usethespringremovaltool(T oroPart
No.92–5771)toremovethespringfromthe
mower-deckpost(Figure85).

Note:For2500Seriesmowerdecks,usea

ratchetinthesquareholeintheidlerarmto
removetensionontheidlerspring(Figure86).

6.Removethebeltfromthemower-deckpulleys
andtheclutchpulley.

7.Installthenewbeltaroundthemowerpulleys
andtheclutchpulleyundertheengine(Figure

84orFigure86).

g027729

g028279

Figure85

1500and2000SeriesMowerDecks

1.Spring-removaltool(T oro
PartNo.92–5771)

2.Idlerspring5.Mowerbelt

3.Mower-deckpost

63

4.Idlerarm

ReplacingtheMowerBelt forRearDischargeMower Decks

ReplacingtheCounter-Rotating
Belt

1.Disengagetheblade-controlswitch(PTO),move

themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait

forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Lowerthemowertothe76mm(3inches)height

ofcut.

4.Lifttheoorpanuptogainaccesstothecenter

pulley.

Figure86

2500SeriesMowerDecks

1.Clutchpulley

2.Mowerbelt

3.Spring-loadedidlerpulley

4.Ratchet

5.Squareholeintheidler
armfortheratchet

8.Installtheidlerspring(Figure84orFigure86).

Note:Makesuretoseatthespringendsinthe

anchorgrooves.

9.Installthebeltcovers(Figure87).

g036865

5.Removetheplasticbeltcover(Figure89).

6.Removethe3boltsholdingthemetalbeltcover
inplaceandremovethemetalbeltcover.

g036862

Figure88

1.Idlerspring4.Idlerpulley

2.Counter-rotatingbelt5.Squareholeintheidler

3.Doublepulley

armfortheratchet

Figure87

7.Usearatchetinthesquareholeintheidlerarm
toremovetensionontheidlerspring(Figure88).

g027730

8.Removethebeltfromthemowerdeckpulley
(Figure88).

9.Removethebeltfromtheremainingpulleys
(Figure88).

10.Routethenewbeltaboundthemowerpulleys.

64

11.Usingtheratchetinthesquarehole,removethe
tensiononthespring,andguidethenewbelt
aroundtheidlerpulley(Figure88).

ReplacingtheMowerBelt

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Lowerthemowertothe76mm(3inches)height
ofcut.

4.Removethebeltcovers(Figure89).

Figure89

5.Removethecounter-rotatingbelt;referto

ReplacingtheCounter-RotatingBelt(page64).

6.Usearatchetinthesquareholeintheidlerarm
toremovetensionontheidlerspring(Figure90).

7.Removethebeltfromthemower-deckpulleys
andtheclutchpulley.

8.Installthenewbeltaroundthemowerpulleys
andtheclutchpulleyundertheengine(Figure

90).

g036863

Figure90

Reardischargemowerdeckshown

1.Mowerbelt

2.Spring-loadedidlerpulley4.Counter-rotatingbelt

3.Squareholeintheidler
armfortheratchet

9.Usingtheratchetinthesquarehole,installthe
beltaroundthespring-loadedidlerpulley(Figure

90).

g009036

Makesurethatthespringendsareseatedin
theanchorgrooves.

10.Installthebeltcovers(Figure91).

g009037

Figure91

65

ReplacingtheHydraulic Pump-DriveBelt

1.Disengagetheblade-controlswitch(PTO)and
settheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Removethemowerbelt;refertoReplacingthe

MowerBeltforSideDischargeMowerDecks
(page63)orReplacingtheMowerBeltforRear
DischargeMowerDecks(page64).

4.Raisethemachineandsupportitwithjack
stands(Figure93).

5.Removetheclutchstop(Figure92).

Figure93

1.Idlerpulley4.Pump-drivebelt

2.Idler-springpost5.Righthydraulic-pump

3.Enginepulley

pulley

6.Lefthydraulic-pumppulley

9.Installtheclutchstop(Figure92).

g036859

Figure92

1.Clutchstop

6.Removetheidlerspringfromthepost(Figure

93).

7.Removetheexistingbeltfromthe
hydraulic-unit-drivepulleysandtheengine
pulley.

8.Installthenewbeltaroundtheenginepulleyand
the2hydraulic-pumppulleys(Figure93).

10.Installthemowerbelt;refertoBeltMaintenance

(page63).

g036860

66

ControlsSystem
Maintenance

Adjustingthe Control-HandlePosition

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

Adjustingtheheight:

Youcanadjustthemotioncontrollevershigher
orlowerformaximumcomfort.

A.Removethehardwareholdingthecontrol

levertothecontrol-armshaft.

C.Repeattheadjustmentfortheopposite

controllever.

g009195

Figure95

Figure94

1.Bolts

2.Slottedhole4.Control-armshaft

B.Movethecontrollevertothenextsetof

holes.Securetheleverwiththehardware.

C.Repeattheadjustmentfortheopposite

controllever.

AdjustingtheTilt

A.Loosentheupperboltholdingthecontrol

levertothecontrolarmshaft.

B.Loosenthelowerboltjustenoughtopivot

thecontrolleverforeoraft.Tightenboth
boltstosecurethecontrolinthenew
position.

3.Controllever

3.Iftheendsofthelevershitagainsteachother,
refertoAdjustingtheMotion-ControlLinkage

(page67).

Adjustingthe Motion-ControlLinkage

Locatedoneithersideofthemachine,belowtheseat
arethepumpcontrollinkages.Rotatingtheendnut
witha1/2inchdeepsocketwrenchallowsnetuning
adjustmentssothatthemachinedoesnotmovein
neutral.Anyadjustmentsshouldbemadeforneutral
positioningonly.

g035858

WARNING

Enginemustberunninganddrivewheels
mustbeturningsoadjustmentscanbe
performed.Contactwithmovingpartsorhot
surfacesmaycausepersonalinjury.

Keepyourngers,hands,andclothingclear
ofrotatingcomponentsandhotsurfaces.

1.Priortostartingtheengine,pushthedecklift
pedalandremovetheheightofcutpin.Lower
decktotheground.

2.Raisetherearofmachineupandsupportwith
jackstands(orequivalentsupport)justhigh
enoughtoallowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseat
safetyswitch,locatedunderthebottomcushion
oftheseat.

67

Note:Theswitchisapartoftheseatassembly.

4.T emporarilyinstallajumperwireacrossthe

terminalsintheconnectorofthemainharness.

5.Starttheengine.Runtheengineatfullthrottle
andreleasetheparkingbrake.

Note:Ensurethattheparkingbrakeisengaged

andthatthemotion-controlleversareouttostart
theengine.Y oudonothavetobeintheseat.

6.Runthemachineatleast5minuteswiththe
driveleversinthefullforwardspeedtobring
hydraulicuiduptooperatingtemperature.

Note:Themotion-controllevermustbe

inneutralwhilemakinganynecessary
adjustments.

7.Bringthemotion-controlleversintotheNEUTRAL
position.

8.Checkandensurethatthecontrol-platetabs
touchthereturn-to-neutralplatesonthe
hydraulicunits.

g036753

Figure96

9.Adjustthepump-control-rodlengthsbyturning
thenutintheappropriatedirectionuntilthe
wheelsslightlycreepinreverse(seeFigure96).

10.Movethemotion-controlleverstotheREVERSE
positionandwhileapplyingslightpressureto
thelever,allowthereverseindicatorspringsto
bringtheleversbacktoneutral.

Note:Thewheelsmuststopturningorslightly

creepinreverse.

Note:Y oumayneedtoremovethe

motion-controlcovertogainaccess.

1.Nut4.Return-to-neutralplate

2.Stationaryplate

3.Controlplate

5.Tabstouchingreturnto
neutralplate

11.Shutoffthemachine.

12.Removethejumperwirefromthewireharness
andplugtheconnectorintotheseatswitch.

13.Removethejackstands.

14.Raisethemowerdeckandinstalltheheightof
cutpin.

15.Checkandensurethatthemachinedoesnot
creepinneutralwiththeparkbrakedisengaged.

68

HydraulicSystem
Maintenance

HydraulicSystemSafety

•Ensurethatallhydraulic-uidhosesand

linesareingoodconditionandallhydraulic
connectionsandttingsaretightbefore
applyingpressuretothehydraulicsystem.

•Keepyourbodyandhandsawayfrompinhole

leaksornozzlesthatejecthigh-pressure
hydraulicuid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulic

systembeforeperforminganyworkonthe
hydraulicsystem.

•Seekimmediatemedicalattentionifuid

isinjectedintoskin.Injecteduidmustbe
surgicallyremovedwithinafewhoursbya
doctor.

g037051

Figure97

1.Engine2.Expansiontank

ServicingtheHydraulic System

HydraulicFluidType:Toro

hydraulicuid(preferred)orMobil115W-50oil.

Important:Usetheuidspecied.Otheruids

couldcausesystemdamage.

HydraulicSystemCapacity(withltersremoved):

4.45L(150oz)

CheckingtheHydraulicFluidLevel

ServiceInterval:Beforeeachuseordaily

1.Allowthehydraulicuidtocooldown.Check
theoillevelwhentheoiliscold.

2.Checkexpansionreservoirandifnecessary
addT oro
FULLCOLDline.

®

HYPR-OIL

®

HYPR-OIL

™

500hydraulicuidtothe

™

500

69

Changingthe Hydraulic-SystemFilters andFluid

ServiceInterval:Aftertherst75hours—Changethe

hydraulic-systemltersanduid.

Every500hours—Aftertheinitial
change—changethehydraulic-system
ltersanduidwhenusingT oro
500oil(changeitmoreoftenundersevere
conditions).

Every250hours—Aftertheinitial
change—changethehydraulic-system
ltersanduidwhenusingMobil115W50uid
(changeitmoreoftenundersevereconditions).

®

HYPR-OIL

™

g017444

Figure98

Rightsideshown

Changetheltersandoilatthesametime.Donot
usetheoilagain.Purgeanyairinthesystemafteryou
installthenewltersandaddoil.RefertoBleeding

theHydraulicSystem(page72).

Repeatthebleedingprocessuntiltheoilremains
attheFULLCOLDlineinthereservoirafterpurging.

Failuretoproperlyperformthisprocedurecan
resultinirreparabledamagetothetransaxledrive
system.

RemovingHydraulic-System
Filters

1.Shutofftheengine,waitforallmovingpartsto
stop,allowtheenginetocool,removethekey,
andengagetheparkingbrake.

2.Locatethelterandguardsoneach
transaxle-drivesystem(Figure98).

3.Removethe3screwssecuringthelterguard
andguard(Figure98).

1.Transaxledrive

2.Oillter

3.Filterguard

4.Carefullycleantheareaaroundthelters.

4.Screws

5.Ventplug

Important:Donotallowdirttoenterthe

hydraulicsystem,orcontaminationmay
occur.

5.Placeadrainpanbelowtheltertocatchthe
oilthatdrainswhenthelterandventplugsare
removed.

6.Locateandremovetheventplugoneach
transmission

7.Unscrewtheltertoremoveit,andallowtheoil
todrainfromthedrivesystem.

8.Repeatthisprocedureforbothlters.

70

InstallingtheHydraulic-System
Filters

1.Applyathincoatofoilonthesurfaceofthe
rubbersealofeachlter.

2.Turnthelterclockwiseuntiltherubberseal
contactsthelteradapter,thentightenthelter
anadditional3/4to1fullturn.

3.Repeatfortheoppositelter.

4.Installthelterguardsovereachlterthatyou
previouslyremoved.

5.Usethe3screwstosecurethelterguards.

6.Verifythattheventplugsareremovedbefore
addingtheoil.

7.Slowlypourthespeciedoilthroughthe
expansionreservoiruntiloilcomesoutof1of
thevent-plugholes.

8.Installtheventplug.

9.T orquetheplugto20N∙m(15ft-lb).

10.Continuetoaddoilthroughtheexpansion
reservoiruntiloilcomesoutoftheremaining
vent-plugholeonthesecondtransmission.

11.Installtheoppositeventplug.

12.T orquetheplugto20N∙m(15ft-lb).

g027477

Figure99

13.Continuetoaddoilthroughtheexpansion
reservoiruntilitreachestheFULLCOLDlineon
theexpansionreservoir.

14.ProceedtoBleedingtheHydraulicSystem

(page72).

Important:FailuretoperformtheBleeding

theHydraulicSystemprocedureafter

changinghydraulicltersandoilcanresult
inirreparabledamagetothetransaxledrive
system.

71

BleedingtheHydraulicSystem

1.Raisetherearofmachineandsupportitwith
jackstands(orequivalentsupport)justhigh
enoughtoallowthedrivewheelstoturnfreely.

Figure100

1.Jackingpoints

2.Starttheengine,movethethrottlecontrolahead
tothe1/2throttleposition,anddisengagethe
parkingbrake.

A.Movethebypassleversintothepushingthe

machineposition.Withthebypassvalves
openandtheenginerunning,slowlymove
themotion-controlleversinbothforward
andreverse5or6times.

MowerDeck Maintenance

LevelingtheMowerDeck

AdjustingtheSide-to-Side
LevelingandtheBladeSlope

1.Positionthemoweronaatsurface.

2.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

3.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe

g017625

operatingposition.

4.Checkthetirepressureinthedrivetires.Refer
toCheckingtheTirePressure(page60).

5.Positionthemowerdeckinthetransport-lock
position.

6.Carefullyrotatethebladesfromsidetoside.

7.Measurebetweenthebladetipandtheat
surface(Figure101).Ifbothmeasurementsare
notwithin5mm(3/16inch),adjusttheleveling;
continuewiththisprocedure.

B.Movethebypassleversintotheoperating

themachineposition.

C.Withthebypassvalveclosedandthe

enginerunning,slowlymovethecontrol
leverinbothforwardandreversedirections
5to6times.

D.Shutofftheengineandchecktheoillevelin

theexpansionreservoir.Addthespecied
oiluntilitreachestheFULLCOLDlineonthe
expansionreservoir.

3.Repeatstep2untilalltheairiscompletely
purgedfromthesystem.

Note:Whenthetransaxleoperatesatnormal

noiselevels,movessmoothlyforward,and
reversesatnormalspeeds,itispurged.

4.Checktheoillevelintheexpansionreservoira
naltime.Addthespeciedoilasuntilitreaches
theFULLCOLDlineontheexpansionreservoir.

Figure101

1.Bladessidetoside

2.Bladetip

8.Checkthefront-to-rearbladelevel(Figure102).
Ensurethefrontbladetipislowerthantherear
bladetipasshownintheblockheightandrake
table.Ifadjustmentisneeded,continuewiththis
procedure.

3.Measurefromthetipofthe
bladetotheatsurface
here.

g037879

72

Figure102

11.Place2blocks(seeBlockHeightandRake
Table)undertherearedgeofthecuttingdeck
skirt;1oneachsideofthecuttingdeck(Figure

104).

12.Settheheight-of-cutlevertothe3inch(76mm)
position.

13.Place2blocksundereachsideofthefrontedge
ofthedeck,butnotundertheanti-scalproller
bracketsorwelds.

g037880

1.Bladesfronttorear3.Measurefromthetipofthe
bladetotheatsurface
here.

2.Bladetip

9.Settheanti-scalprollerstotopholesorremove

themcompletelyforthisadjustment.

10.For60-inchmowerdecksonly:

A.Raisethedecktothetransportposition

(12.7cmor5inches).

B.Slowlyloosentheadjustingscrewonthe

lift-assistspringuntilyoucanremovethe
screw(seeFigure103).

Note:Savethescrewforinstallation.

Figure104

Bottomview

1.Block—7.3cm(2.87
inches)

2.Welds

BlockHeightandRakeT able

Deck
Size

Allmower
decks

14.Carefullyrotatethebladessidetoside(Figure

101).

FrontBlockHeightRake

7.3cm(2.87inches)4.8to6.4mm(3/16to1/4
inch)

g038090

1.Adjustingscrew

2.Bracket

15.Loosenthelocknuts(Figure105)onall4
cornersandensurethatthemowerdeckis
sittingsecurelyonall4blocks.

16.Removeanyslackfromthedeckhangersand
makesurethedeck-liftfootleverispushedback
againstthestop.

17.Tightenthe4locknuts.

g035850

Figure103

Reardischargemowerdeckshown

3.Setthegapto22to29
mm(7/8to1-1/8inch).

73

Figure105

1.Locknuts3.Deckhanger

2.Deckliftarm4.Chain

18.Ensurethattheblockstsnuglyunderthedeck
skirtandthatallattachmentboltsaretight

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades
sharp.Forconvenientsharpeningandreplacement,
keepextrabladesonhand.

BladeSafety

Awornordamagedbladecanbreak,andapiece
ofthebladecouldbethrownatyouorbystanders,
resultinginseriouspersonalinjuryordeath.Tryingto
repairadamagedblademayresultindiscontinued
safetycerticationoftheproduct.

•Inspectthebladeperiodicallyforwearordamage.

g035851

•Usecarewhencheckingtheblades.Wrapthe

bladesorweargloves,andusecautionwhen
servicingtheblades.Onlyreplaceorsharpenthe
blades;neverstraightenorweldthem.

•Onmulti-bladedmachines,takecareasrotating1

bladecancauseotherbladestorotate.

19.Continuelevelingthedeckbycheckingthe
front-to-rearbladeslope.

20.Checkthebladesforlevelnessandrepeatdeck
levelingprocedureifnecessary.

21.For60-inchmowerdecksonly:

A.Raisethedecktothetransportposition

(12.7cmor5inches).

B.Installthelift-assistspringadjustingscrew

previouslyremovedinstep10.

C.Setthegapbetweenthespringandthe

bracketto22to29mm(7/8to1-1/8inch).

BeforeInspectingorServicingthe
Blades

1.Parkthemachineonalevelsurface,Disengage
theblade-controlswitch(PTO),andsetthe
parkingbrake.

2.Turntheignitionkeytooff.Removethekey,and
disconnectthespark-plugwiresfromthespark
plugs.

74

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure106).

2.Iftheedgesarenotsharporhavenicks,remove
andsharpentheblade;refertoSharpeningthe

Blades(page77).

3.Inspecttheblades,especiallyinthecurvedarea.

4.Ifyounoticeanycracks,wear,oraslotforming
inthisarea,immediatelyinstallanewblade
(Figure106).

g000975

Figure107

Figure106

1.Cuttingedge3.Wear/slotforming

2.Curvedarea4.Crack

CheckingforBentBlades

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.Rotatethebladesuntiltheendsfaceforward
andbackward(Figure107).

4.Measurefromalevelsurfacetothecutting
edge,positionA,oftheblades(Figure107).

1.Measureherefromblade
tohardsurface

2.PositionA

5.Rotatetheoppositeendsofthebladesforward.

g006530

6.Measurefromalevelsurfacetothecuttingedge

ofthebladesatthesamepositionasinstep4.

Note:Thedifferencebetweenthedimensions

obtainedinsteps4and5mustnotexceed3mm
(1/8inch).

Note:Ifthisdimensionexceeds3mm

(1/8inch),thebladeisbentandmustbe
replaced.

WARNING

Abladethatisbentordamagedcould
breakapartandcouldseriouslyinjureor
killyouorbystanders.

•Alwaysreplacebentordamaged
bladewithanewblade.

•Donotleorcreatesharpnotchesin
theedgesorsurfacesoftheblade.

75

ChangingtheBladesforSide

ChangingtheBladesforRear

DischargeMowerDecks

RemovingtheBladesforSideDischarge
MowerDecks

Replaceabladeifithitsanobject,ifthebladeisout
ofbalance,orifthebladeisbent.T oensureoptimum
performanceandcontinuedsafetyconformanceof
themachine,usegenuineTororeplacementblades.
Replacementbladesmadebyothermanufacturers
mayresultinnonconformancewithsafetystandards.

1.Holdthespindleshaftwithawrench.

2.Removethebladebolt,curvedwasher,and
bladefromthespindleshaft(Figure108).

DischargeMowerDecks

RemovingtheBladesforRearDischarge
MowerDecks

Replaceabladeifithitsanobject,isoutofbalance,
orifitisbent.T oensureoptimumperformanceand
continuedsafetyconformanceofthemachine,use
genuineTororeplacementblades.Replacement
bladesmadebyothermanufacturersmayresultin
nonconformancewithsafetystandards.

1.Holdthebladeendusingaragorathickly
paddedglove.

2.Removetheleftandcenterbladebolt,curved
washer,andbladefromthespindleshaft(Figure

109).

3.Removetherightbladebolt(left-handthreaded
bolt),curvedwasher,andbladefromthespindle
shaft(Figure110).

Note:Notethetypebladeandwhereeach

bladeisinstalled.SeeFigure110forthecorrect
position.

Figure108

1.Sailareaoftheblade

2.Blade

3.Curvedwasher

4.Bladebolt

5.Spindleshaft

InstallingtheBladesforSideDischarge
MowerDecks

1.Installthebladeontothespindleshaft(Figure

108).

Important:Thecurvedpartoftheblade

mustpointupwardtowardtheinsideofthe
mowertoensurepropercutting.

2.Installthecurvedwasherandbladebolt(Figure

108).

Note:Installthecurved-washerconetoward

thebolthead.

3.T orquethebladeboltto115to150N∙m(85to
110ft-lb).

g017443

g017443

Figure109

LeftandCenterSpindleShown

1.Sailareaoftheblade

2.Blade

3.Curvedwasher

4.Bladebolt

5.Spindleshaft

InstallingtheBladesforRearDischarge
MowerDecks

Important:Therightbladeonthismower

deckiscounter-rotatingandusesaleft-hand

76

threadedbladebolt.UseFigure110forthecorrect
placementofthemowerblades.

1.Installtheleftandcenterblades,curved
washers,andbladeboltstothespindleshafts
(Figure109andFigure110).

Note:Ensurethecurvedpartofthebladeis

pointingupwardtowardtheinsideofthemower
decktoensurepropercutting.

Note:Ensurethecurved-washerconeis

installedtowardthebolthead(Figure109).

2.Installtherightblade,curvedwasher,andblade
bolt(left-handthreadedbolt)tothespindleshaft
(Figure109andFigure110).

3.T orquethebladeboltsto115to150N∙m(85to
110ft-lb);refertoFigure110.

g000276

Figure111

1.Sharpenattheoriginalangle

2.Checkthebalanceofthebladebyputtingiton
abladebalancer(Figure112).

Note:Ifthebladestaysinahorizontalposition,

thebladeisbalancedandreadytouse.

g000277

Figure112

1.Blade2.Balancer

3.Ifthebladeisnotbalanced,lesomemetaloff
theendofthesailareaonly(Figure108).

4.Repeatthisprocedureuntilthebladeis
balanced.

Figure110

1.Frontofmowerdeck4.Counter-rotatingblade

2.Right-handthreadedblade
bolts

3.Regularblades

5.Left-handthreadedblade
bolt

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatboth
endsoftheblade(Figure111).

Note:Maintaintheoriginalangle.

Note:Thebladeretainsbalanceifyouremove

thesameamountofmaterialfrombothcutting
edges.

g024248

77

RemovingtheMowerDeck

ReplacingtheGrass

Beforeservicingorremovingthemowerdeck,lock
outthespring-loadeddeckarms.

1.Shutofftheengine,waitforallmovingparts
tostop,andremovekey .Engagetheparking
brake.

2.Removetheheightadjustmentpinandlowerthe
decktotheground.

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

4.Removethebeltcovers.

5.Loosenthemowerdeckidlerandremovethe
mowerbelt;refertoBeltMaintenance(page63).

6.Removetheboltsandnutsfromthefrontofthe
plateunderthefootrest.

7.Removeandretaintheboltsandnutsonboth
sidesofthemachine(Figure113).

Deector

SideDischargeMowersOnly

WARNING

Anuncovereddischargeopeningcouldallow
thelawnmowertothrowobjectstowardyou
orbystanders,resultinginseriousinjury.
Also,contactwiththebladecouldoccur.

Donotoperatethelawnmowerunlessyou
installacoverplate,mulchplate,grass
deector,orbagger.

1.Removethelocknut,bolt,spring,andspacer
holdingthedeectortothepivotbrackets
(Figure114).

2.Removethedamagedorworngrassdeector
(Figure114).

Figure113

1.Removethenutsandboltshere.

2.Removethenutsandboltshere.

8.Slidethedeckouttotherightsideofthe
machine.

g036866

g015594

Figure114

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

3.Placethespacerandthespringontograss
deector.

4.Place1J-hookendofthespringbehindthe
deckedge.

5.Springinstalled

7.J-hookendofspring

Note:Makesurethat1J-hookendofthe

springisinstalledbehindthedeckedgebefore
installingtheboltasshowninFigure1 14.

5.Installtheboltandthenut.

6.Place1J-hookendofthespringaroundthe
grassdeector(Figure1 14).

Important:Thegrassdeectormustbeable

torotate.Liftthedeectoruptothefullopen

78

positionandensurethatitrotatesintothe
fulldownposition.

Cleaning

CleaningundertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagetheblade-controlswitch(PTO),move
themotion-controlleverstotheNEUTRAL-LOCK
position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait
forallmovingpartstostopbeforeleavingthe
operatingposition.

3.RaisethemowertotheTRANSPORTposition.

DisposingofWaste

Engineoil,batteries,hydraulicuid,andengine
coolantarepollutantstotheenvironment.Disposeof
theseaccordingtoyourstateandlocalregulations.

79

Storage

CleaningandStorage

1.Disengagetheblade-controlswitch(PTO),set
theparkingbrake,andturntheignitionkeyto
off.Removethekey.

2.Removegrassclippings,dirt,andgrimefrom
theexternalpartsoftheentiremachine,
especiallytheengineandhydraulicsystem.
Cleandirtandchafffromtheoutsideofthe
engine-cylinder-headnsandblowerhousing.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Shutofftheengine,allowittocool,and

drainthefueltank;refertoServicingthe

FuelT ank(page56).

D.Starttheengineandrunituntilitshutsoff.

E.Disposeoffuelproperly.Recycleasper

localcodes.

Important:Donotstore

stabilizer/conditionedfuelover
90days.

Important:Youcanwashthemachine

withmilddetergentandwater.Donot
pressure-washthemachine.Avoid
excessiveuseofwater,especiallynearthe
controlpanel,engine,hydraulicpumps,and
motors.

3.Checkthebrake.

4.Servicetheaircleaner;refertoEngine

Maintenance(page40).

5.Greasethemachine;refertoLubrication(page

38).

6.Changethecrankcaseoil;refertoEngine

Maintenance(page40).

7.Checkthetirepressure;refertoCheckingthe

TirePressure(page60).

8.Changethehydrauliclters;refertoChanging

theHydraulic-SystemFiltersandFluid(page

70).

9.Chargethebattery;refertoChargingtheBattery

(page58).

10.Scrapeanyheavybuildupofgrassanddirt
fromtheundersideofthemower,thenwashthe
mowerwithagardenhose.

13.Checkandtightenallbolts,nuts,andscrews.
Repairorreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paint
isavailablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageor
storagearea.

16.Removethekeyfromtheignitionswitch
andkeepitoutofreachofchildrenorother
unauthorizedusers.

17.Coverthemachinetoprotectitandkeepitclean.

Note:Runthemachinewiththeblade-control

switch(PTO)engaged,andtheengineathigh
idlefor2to5minutesafterwashing.

11.Checktheconditionoftheblades;referto

ServicingtheCuttingBlades(page74).

12.Preparethemachineforstoragewhennon-use
occursover30days.Preparethemachinefor
storageasfollows:

A.Addapetroleum-based

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

Note:Afuelstabilizer/conditionerismost

effectivewhenmixedwithfreshfueland
usedatalltimes.

80

Troubleshooting

Problem

Thestarterdoesnotcrank.

Theenginedoesnotstart,startshard,or
failstokeeprunning.

PossibleCauseCorrectiveAction

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.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.

1.Movetheblade-controlswitch(PTO)
tothedisengagedposition.

2.Settheparkingbrake.

3.Ensurethatthemotion-controllevers
areintheNEUTRAL-LOCKposition.

4.Sitontheseat.

5.Chargethebattery.

6.Checktheelectricalconnectionsfor
goodcontact.

8.ContactanAuthorizedServiceDealer.

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.

Theenginelosespower.

Theengineoverheats.

Themowerpullstotheleftorright(with
leversfullyforward)

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.Thetirepressureinthedrivetiresis
notcorrect.

2.Cleantheair-cleanerelement.

4.Removetheobstructionfromthe
coolingnsandtheairpassages.

7.ContactanAuthorizedServiceDealer.

3.Removetheobstructionfromthe
coolingnsandtheairpassages.

2.Adjustthetirepressureinthedrive
tires.

81

Problem

PossibleCauseCorrectiveAction

Themachinedoesnotdrive.

Themachinevibratesabnormally .

Themachineproducesanunevencutting
height.

1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.

2.Thepumpbeltisworn,loose,or
broken.

3.Thepumpbeltisoffapulley.3.Changethebelt.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

5.Thehydraulicoillevelislowortoohot.5.Addhydraulicoiltothereservoirsor

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.

2.Changethebelt.

letitcooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

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

6.ContactanAuthorizedServiceDealer.

Thebladesdonotrotate.

Theclutchdoesnotengage.

1.Themowerdeckbeltisdamaged,
worn,loose,orbroken.

2.Themowerdeckbeltisoffthepulley.

3.Thepumpdrivebeltisworn,loose,or
broken.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

1.Thefuseisblown.

2.Thereislowvoltagesupplyatthe
clutch.

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead

5.Therotor/armatureairgapistoolarge.

1.Installanewdeckbelt.

2.Installthemowerbeltonthedeck
pulleyandchecktheidlerpulley,idler
arm,andspringforcorrectposition
andfunction.

3.Checkthebelttensionorinstallanew
belt.

1.Replacethefuse.Checkthecoil
resistance,batterycharge,charging
system,andwiringconnections,and
replacecomponentsifnecessary.

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

wireorelectricalsystem.Cleanthe
connectorcontacts.

Removetheshimorreplacetheclutch.

5.

82

Schematics

WireDiagram—ToroEngines(Rev.A)

83

g036150

WireDiagram—KohlerEngines(Rev.A)

84

g036151

WireDiagram—KawasakiEngines(Rev.A)

85

g037072

Notes:

Notes:

TheToroWarranty

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Landscape

Equipment
(LCE)

ConditionsandProductsCovered

TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuanttoanagreement
betweenthem,jointlypromisetorepairtheT oroProductslistedbelowifdefectivein
materialsorworkmanship.

Thefollowingtimeperiodsapplyfromtheoriginaldateofpurchase:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1

1yearCommercialUse

3

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1

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

2

2

2

2

KohlerEFI–3years

ZMaster

•Engines

ZMaster

•Engines

ZMaster

•Engines

TITANHD1500Series

®

3

®

7000SeriesMowers

3

®

8000SeriesMowers

3

6000SeriesMowers

5yearsor1,200hours

Kawasaki–3years

5yearsor1,200hours

2years

2yearsor1,200hours

2years

4yearsor500Hours

2

2

2

2

•EnginesToro–4yearsor500hours

TITANHD2500Series

•Engines

TITANHD2000Series

•Engines

3

Kawasaki–3years

4yearsor750Hours

4yearsor1,000Hours

3

Kohler–3years

2

2

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

1

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

2

Whicheveroccursrst.

3

SomeenginesusedonT oroProductsarewarrantedbytheenginemanufacturer.

OwnerResponsibilities

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

InstructionsforObtainingWarrantyService

IfyouthinkthatyourToroProductcontainsadefectinmaterialsorworkmanship,
followthisprocedure:

1.ContactanyAuthorizedToroServiceDealertoarrangeserviceattheir
dealership.Tolocateadealerconvenienttoyou,accessourwebsiteat
www.T oro.com.Y oumayalsocallthenumberslistedinitem#3tousethe
24-hourT oroDealerlocatorsystem.

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

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith
theassistanceprovided,contactusat:

ToroWarrantyCompany

CustomerCareDepartment,RLCDivision

811 1LyndaleAvenueSouth

Bloomington,MN55420-1 196

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

888-865-5691(Canadacustomers)

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.

NeitherTheToroCompanynorT oroW arrantyCompanyisliableforindirect,
incidentalorconsequentialdamagesinconnectionwiththeuseoftheToro
Productscoveredbythiswarranty,includinganycostorexpenseofproviding
substituteequipmentorserviceduringreasonableperiodsofmalfunctionor
non-usependingcompletionofrepairsunderthiswarranty.

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

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages,
orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions
andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights
whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry ,
province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtainingguaranteeinformation,contacttheT oroimporter.Ifallother
remediesfail,youmaycontactusatToroWarrantyCompany .

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalToroDealer.

374-0252RevI