Toro Z Master 3000 SERIES Operator's Manual

Download

FormNo.3380-770RevA

ZMaster

Commercial3000

SeriesRidingMower

with48in,52in,or60inTURBOFORCE

Side

DischargeMower

ModelNo.74952—SerialNo.314000001andUp

ModelNo.74953—SerialNo.314000001andUp

ModelNo.74957—SerialNo.314000001andUp

ModelNo.78953—SerialNo.314000001andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3380-770*A

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadianICES-002.

Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisavailableas anoption.Ifyourequireasparkarrester,contactyour AuthorizedToroServiceDealer.

GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.

Important:ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperatetheengine onanyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.

Theenclosed

Engine Owner's Man ual

issuppliedfor informationregardingtheUSEnvironmentalProtection Agency(EPA)andtheCaliforniaEmissionControl Regulationofemissionsystems,maintenance,and warranty.Replacementsmaybeorderedthroughthe enginemanufacturer.

Introduction

Thisrotary-blade,ridinglawnmowerisintendedtobeused byresidentialhomeownersorprofessional,hiredoperators. Itisdesignedprimarilyforcuttinggrassonwell-maintained lawnsonresidentialorcommercialproperties.Itisnot designedforcuttingbrushorforagriculturaluses.

Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely .

YoumaycontactTorodirectlyatwww .Toro.comforproduct andaccessoryinformation,helpndingadealer,ortoregister yourproduct.

Wheneveryouneedservice,genuineToroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready .

Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.

Contactusatwww.T oro.com.

PrintedintheUSA

AllRightsReserved

Contents

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

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

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

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

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

ProductOverview.........................................................12

Controls...............................................................12

Specications........................................................13

Operation....................................................................14

AddingFuel...........................................................14

CheckingtheEngineOilLevel.................................15

BreakingInaNewMachine.....................................15

UsingtheRolloverProtectionSystem(ROPS)............15

ThinkSafetyFirst...................................................16

OperatingtheParkingBrake....................................17

OperatingtheMowerBladeControlSwitch

(PTO)...............................................................17

OperatingtheThrottle............................................18

OperatingtheChoke...............................................18

OperatingtheIgnitionSwitch..................................18

UsingtheFuel-shutoffValve....................................18

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

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

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

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

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

AdjustingtheAnti-scalpRollers................................23

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

PositioningtheFlowBafe......................................25

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

UsingtheDriveWheelReleaseValves.......................26

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

LoadingtheMachine..............................................26

TransportingtheMachine........................................27

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

Maintenance.................................................................29

RecommendedMaintenanceSchedule(s)......................29

Lubrication...............................................................30

GreasingandLubrication........................................30

WheretoGreasetheMower.....................................30

LubricatingtheCasterWheelHubs...........................31

EngineMaintenance..................................................32

ServicingtheAirCleaner.........................................32

ServicingtheEngineOil..........................................33

ServicingtheSparkPlugs.........................................36

CheckingtheSparkArrester(ifequipped)..................37

FuelSystemMaintenance...........................................37

ReplacingtheFuelFilter..........................................37

ServicingtheFuelTank...........................................38

ElectricalSystemMaintenance....................................38

ServicingtheBattery...............................................38

ServicingtheFuses.................................................39

DriveSystemMaintenance.........................................40

CheckingtheSeatBelt.............................................40

CheckingtheRolloverProtectionSystem(ROPS)

Knobs...............................................................40

AdjustingtheTracking............................................41

CheckingtheTirePressure......................................41

CheckingtheWheelLugNuts..................................42

CheckingtheWheelHubSlottedNut........................42

AdjustingtheCasterPivotBearing............................42

UsingtheClutchShim............................................42

CoolingSystemMaintenance......................................44

CleaningtheEngineScreenandEngineOil

Cooler...............................................................44

CleaningtheEngineCoolingFinsand

Shrouds.............................................................44

CheckingandCleaningtheHydraulicUnits................45

BrakeMaintenance....................................................46

AdjustingtheParkingBrake.....................................46

BeltMaintenance......................................................47

InspectingtheBelts................................................47

ReplacingtheMowerBelt........................................47

ReplacingtheHydraulicPumpDriveBelt...................48

ControlsSystemMaintenance.....................................49

AdjustingtheControlHandlePosition......................49

AdjustingtheMotionControlLinkage......................50

AdjustingtheMotionControlDamper......................50

AdjustingtheMotionControlNeutralLock

Pivot.................................................................51

HydraulicSystemMaintenance....................................51

ServicingtheHydraulicSystem.................................51

MowerDeckMaintenance...........................................53

LevelingtheMowerDeck........................................53

ServicingtheCuttingBlades.....................................55

RemovingtheMowerDeck.....................................58

ReplacingtheGrassDeector..................................60

Cleaning...................................................................60

CleaningUndertheMower......................................60

WasteDisposal.......................................................60

Storage........................................................................61

CleaningandStorage..............................................61

Troubleshooting...........................................................62

Schematics...................................................................64

Safety

Improperuseormaintenanceofthemachinecanresult ininjury.Toreducethepotentialforinjury,complywith thesesafetyinstructionsandalwayspayattentiontothe safetyalertsymbol,whichmeans

Caution, W ar ning ,

Danger

—personalsafetyinstruction.Failuretocomply withtheinstructionmayresultinpersonalinjuryor death.

Thisproductiscapableofamputatinghandsandfeetand throwingobjects.Alwaysfollowallsafetyinstructionsto avoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrassor, whenequippedwithagrassbagger,forcatchingcutgrass. Anyuseforpurposesotherthanthesecouldprovedangerous totheuserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsareadaptedfromANSI B71.4-2012.

Training

•ReadtheOperator'sManualandothertrainingmaterial.If

theoperator(s)ormechanic(s)cannotreadorunderstand theinformationitistheowner'sresponsibilitytoexplain thismaterialtothem.

•Becomefamiliarwiththesafeoperationoftheequipment,

operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The

ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateorservice

theequipment.Localregulationsmayrestricttheageof theoperator.

•Theowner/usercanpreventandisresponsiblefor

accidentsorinjuriesoccurringtopeopleordamageto property.

Preparation

•Evaluatetheterraintodeterminewhataccessoriesand

attachmentsareneededtoproperlyandsafelyperform thejob.Onlyuseaccessoriesandattachmentsapproved bythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety

glasses,andhearingprotection.Longhair,looseclothing, orjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeusedand

removeallobjectssuchasrocks,toys,andwirewhichcan bethrownbythemachine.

•Checkthatoperator'spresencecontrols,safetyswitches,

andshieldsareattachedandfunctioningproperly.Donot operateunlesstheyarefunctioningproperly.

Operation

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholesand

hiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis

engagedbeforestartingtheengine.Onlystarttheengine fromtheoperator'sposition.

•Besureofyourfootingwhileusingthismachine,

especiallywhenbackingup.Walk;donotrun.Never operateonwetgrass.Reducedfootingcouldcause slipping.

•Slowdownanduseextracareonhillsides.Besureto

travelsidetosideonhillsides.Turfconditionscanaffect thestabilityofthemachine.Usecautionwhileoperating neardrop-offs.

•Slowdownandusecautionwhenmakingturnsandwhen

changingdirectionsonslopes.

•Neverraisedeckwiththebladesrunning.

•NeveroperatewiththePTOshieldorotherguardsnot

securelyinplace.Besureallinterlocksareattached, adjustedproperly,andfunctioningproperly.

•Neveroperatewiththedischargedeectorraised,

removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingoroverspeed

theengine.

•Stoponlevelground,disengagedrives,engagethe

parkingbrake(ifprovided),andshutofftheenginebefore leavingtheoperator'spositionforanyreason,including emptyingthecatchersoruncloggingthechute.

•Stopequipmentandinspectbladesafterstrikingobjects

orifanabnormalvibrationoccurs.Makenecessary repairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunit.

•Lookbehindanddownbeforebackinguptobesureof

aclearpath.

•Nevercarrypassengersonthemachine.

•Keeppetsandbystandersaway.

•Slowdownandusecautionwhenmakingturnsand

crossingroadsandsidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddonot

pointitatanyone.

•Donotoperatethemowerundertheinuenceofalcohol

ordrugs.

•Usecarewhenloadingorunloadingthemachineinto

orfromatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,trees,

orotherobjectsthatmayobscurevision.

RolloverProtectionSystem (ROPS)—UseandMaintenance

•TheROPSisanintegralandeffectivesafetydevice.Keep

afoldingROPSintheraisedandlockedpositionanduse theseatbeltwhenoperatingthemachine.

•LowerafoldingROPStemporarilyonlywhenabsolutely

necessary.Donotweartheseatbeltwhenfoldeddown.

•Beawarethereisnorolloverprotectionwhenafolded

ROPSisinthedownposition.

•Becertainthattheseatbeltcanbereleasedquicklyin

theeventofanemergency.

•Checktheareatobemowedandneverfolddowna

foldingROPSinareaswherethereareslopes,dropoffs orwater.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforedrivingunderany objectsanddonotcontactthem.

•KeeptheROPSinsafeoperatingconditionby

periodicallythoroughlyinspectingfordamageand keepingallmountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairorrevise.

•DonotremovetheROPS.

•AnyalterationstoaROPSmustbeapprovedbythe

manufacturer.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwherethereis

anopename,spark,orpilotlightsuchasonawater heateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch equipmentwithaportablecontainer,ratherthanfroma fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete.

•Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

MaintenanceandStorage

•Disengagedrives,settheparkingbrake,stoptheengine

andremovethekeyordisconnectthespark-plugwire. Waitforallmovementtostopbeforeadjusting,cleaning orrepairingthemachine.

•Cleangrassanddebrisfromthecuttingunit,thedrives,

themufers,andtheenginetohelppreventres.Clean upoilorfuelspillage.

•Lettheenginecoolbeforestoringanddonotstorenear

ame.

•Shutoffthefuelwhilestoringortransporting.Donot

storefuelnearamesordrainindoors.

•Parkthemachineonlevelground.Settheparkingbrake.

Neverallowuntrainedpersonneltoservicethemachine.

•Usejackstandstosupportcomponentswhenrequired.

•Carefullyreleasepressurefromcomponentswithstored

energy.

•Disconnectthebatteryorthespark-plugwirebefore

makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Connectthepositiverstand negativelast.

•Usecarewhencheckingtheblades.Wraptheblade(s)or

weargloves,andusecautionwhenservicingthem.Only replaceblades.Neverstraightenorweldthem.

•Keephandsandfeetawayfrommovingparts.Ifpossible,

donotmakeadjustmentswiththeenginerunning.

•Keepallpartsingoodworkingconditionandallhardware

tightened.Replaceallwornordamageddecals.

•Tobestprotectyourinvestmentandmaintainoptimal

performanceofyourToroequipment,countonToro genuineparts.Whenitcomestoreliability,T orodelivers replacementpartsdesignedtotheexactengineering specicationsofourequipment.Forpeaceofmind,insist onTorogenuineparts.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected downandoutwardfromthemachine.

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.

1-403005

54-9220

58-6520

1.Grease

66-1340

68-8340

98-5954

103-2076

105-7798

107-2102

109-7232

1.Fast3.Neutral

2.Slow

4.Reverse

110-2067

110-2068

1.ReadtheOperator'sManual.

114-4466

1.Main,25A

3.Charge,25A

2.PTO,10A

4.Auxiliary,15A

115-7445

1.Greasepulleysandspindles

2.Maintenanceinterval—50hours

116-0205

125–9382

116-0752

1.Latch2.Unlatch

116-1654

116-1716

1.Fuel6.Hourmeter

2.Empty

7.PTO

3.Half

8.Parkingbrake

4.Full9.Neutral

5.Battery

10.Operatorpresenceswitch

116-2643

116-3303

116-4858

116-5944

121-7551

1.PowerT ake-off(PTO)4.Continuousvariable setting

2.Choke5.Slow

3.Fast

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

6.Keepbystandersasafe distancefromthebattery .

2.Nore,opename,or smoking.

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries

3.Causticliquid/chemical burnhazard

8.Batteryacidcancause blindnessorsevereburns.

4.Weareyeprotection9.Flusheyesimmediately withwaterandgetmedical helpfast.

5.ReadtheOperator's

Manual.

10.Containslead;donot discard.

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

109-7069

ProductOverview

G014939

Figure4

1.Height-of-cutdecklift pedal

6.Rollbar

2.Transportlock

7.Seatbelt

3.Parkingbrakelever8.Fuelcap

4.Controls

9.Mowerdeck

5.Motioncontrollevers

10.Casterwheel

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure4andFigure5).

G008951

Figure5

1.PTOSwitch4.Hourmeter/Safety

interlockdisplay/Fuel gauge

2.Choke

5.Ignitionswitch

3.Throttlecontrol6.Fuses

FuelGauge

Thefuelgaugeislocatedwiththehourmeter,andthebars lightupwhentheignitionswitchison(Figure6).

Theindicatorlightappearswhenthefuellevelis low—approximately3.8L(1USgallon)remaininginthe fueltank.

Figure6

1.Fuelgauge(bars)4.Safety-interlocksymbols

2.Batterylight

5.Low-fuelindicatorlight

3.Hourmeter

HourMeter

Thehourmeterrecordsthenumberofhourstheenginehas operated.Itoperateswhentheengineisrunning.Usethese timesforschedulingregularmaintenance(

Figure6).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheindicatewitha blacktrianglethattheinterlockcomponentisinthecorrect position(Figure6).

BatteryIndicatorLight

WhentheignitionkeyisinitiallyturnedtotheRunposition forafewseconds,thebatteryvoltagewillbedisplayedinthe areawherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturnedonand whenthechargeisbelowthecorrectoperatinglevel(Figure

6).

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.Pullthechokeknobup toengageit.

BladeControlSwitch(PTO)

Thebladecontrolswitch(PTO)isusedtoengagetheelectric clutchanddrivethemowerblades.Pulltheswitchupto

engagethebladesandrelease.Todisengagetheblades,push thebladecontrolswitch(PTO)downormoveamotion controlleverintotheneutrallockposition.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhasthree positions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.

Fuel-shutoffValve

Closethefuel-shutoffvalve(undertheseat)when transportingorstoringthemower.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesis availableforusewiththemachinetoenhanceandexpand itscapabilities.ContactyourAuthorizedServiceDealeror Distributororgotowww .T oro.comforalistofallapproved attachmentsandaccessories.

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Width:

48inchDeck52inchDeck60inchDeck

Withoutdeck116.1cm

(45.7inches)

116.1cm(45.7 inches)

134.6cm (53.0inches)

Deector—up137.2cm(54

inches)

146.0cm(57.5 inches)

156.8cm (61.7inches)

Deector— down

161.4cm (63.6inches)

171.8cm(67.6 inches)

192.2cm (75.7inches)

Length:

48inchDeck52inchDeck60inchDeck

Rollbar—up201.2cm

(79.2inches)

201.2cm (79.2inches)

211.1cm (83.1inches)

Roll bar—down

205.5cm (80.9inches)

215.4cm (84.8inches)

Height:

Rollbar—upRollbar—down

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

Weight:

ModelWeight

74952

475kg(1048lb)

74953and78953

492kg(1085lb)

74957

533kg(1170lb)

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan30days

old),unleadedgasolinewithanoctaneratingof87or higher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol(gasohol)

or15%MTBE(methyltertiarybutylether)byvolume isacceptable.EthanolandMTBEarenotthesame. Gasolinewith15%ethanol(E15)byvolumeisnot approvedforuse.Neverusegasolinethatcontainsmore than10%ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85(contains upto85%ethanol).Usingunapprovedgasolinemay causeperformanceproblemsand/orenginedamage whichmaynotbecoveredunderwarranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuelcontainers

overthewinterunlessafuelstabilizerisused.

•Donotaddoiltogasoline.

DANGER

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis6to13 mm(1/4to1/2inch)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatewithouttheentireexhaust systeminplaceandinproperworkingcondition.

DANGER

Incertainconditionsduringfueling,static electricitycancauseasparkwhichcanignitethe gasolinevapors.Areorexplosionfromgasoline canburnyouandothersandcandamageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor onatruckortrailerbed,becauseinteriorcarpets orplastictruck-bedlinersmayinsulatethe containerandslowthelossofanystaticcharge.

•Whenpractical,removegas-poweredequipment fromthetruckortrailerandfueltheequipment withthewheelsontheground.

Ifthisisnotpossible,thenfuelsuchequipment onatruckortrailerfromaportablecontainer, ratherthanfromagasoline-dispensernozzle.

•Ifagasolinedispensermustbeused,keepthe nozzleincontactwiththerimofthefueltank orcontaineropeningatalltimesuntilfuelingis complete.

WARNING

Gasolineisharmfulorfatalifswallowed.Long-term exposuretovaporscancauseseriousinjuryand illness.

•Avoidprolongedbreathingofvapors.

•Keepfaceawayfromnozzleandgastankor conditionerbottleopening.

•Avoidcontactwithskin;washoffspillagewith soapandwater.

UsingFuelStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachinetokeepthe fuelfreshduringstorageof90daysorless.Ifyouarestoring themachineforlonger,drainthefueltank;refertoStorage (page61).

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountoffuelstabilizer/conditionertothe fuel,andfollowthedirectionsofthemanufacturer.

Note:Fuelstabilizer/conditionerismosteffectivewhen mixedwithfreshgasoline.Tominimizethechanceofvarnish depositsinthefuelsystem,usefuelstabilizeratalltimes.

FillingtheFuelTank

1.Parkthemachineonlevelground.

2.Shuttheengineoffandsettheparkingbrake.

3.Cleanaroundthefuel-tankcapandremoveit.Add regularunleadedgasolinetothefueltankuntilthelevel is6to13mm(1/4to1/2inch)belowthebottom ofthellerneck.Thisspaceinthetankallowsthe gasolinetoexpand.Donotllthefueltankcompletely full;referto(

Figure7).

G009189

G012429

Figure7

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,checktheoil levelintheenginecrankcase;refertoCheckingtheEngine OilLevel.

BreakingInaNewMachine

Newenginestaketimetodevelopfullpower.Mowerdecks anddrivesystemshavehigherfrictionwhennew,placing additionalloadontheengine.Allow40to50hoursof break-intimefornewmachinestodevelopfullpowerand bestperformance.

UsingtheRolloverProtection System(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraisedlockedpositionandusethe seatbelt.

Ensurethattherearpartoftheseatissecuredwith theseatlatch.

WARNING

Thereisnorolloverprotectionwhentherollbaris inthedownposition.

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbaris inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearancepermits.

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

Important:Lowertherollbaronlywhenabsolutely necessary.

1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sothatthey arenotengaged(Figure8).

3.Lowertherollbartothedownposition(Figure8).

Figure8

1.ROPSknob

3.Rollbarintheupright position

2.PullROPSknoboutand rotate90degrees

4.Rollbarinthefolded position

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

5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins(Figure

8).Pushontherollbarandensurethatbothpinsare engaged.

Important:Alwaysusetheseatbeltwiththeroll barinthefullyraisedposition.

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthesafety section.Knowingthisinformationcouldhelpyouor bystandersavoidinjury.

DANGER

Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Thereisnorolloverprotectionwhentherollbaris down.

Alwayskeeptherollbarinthefullyraisedand lockedpositionandusetheseatbelt.

Readandfollowtherolloverprotectioninstructions andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan15degrees.

•Reducespeedanduseextremecautionon slopes.

•Avoidsuddenturnsorrapidspeedchanges.

Figure9

1.SafeZone—usethe ZMasterhereonslopes lessthan15degreesor atareas.

3.Water

2.DangerZone—usea walk-behindmowerand/or ahandtrimmeronslopes greaterthan15degrees andneardrop-offsand water.

CAUTION

Thismachineproducessoundlevelsinexcessof 85dBAattheoperator’searandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Theuseofprotectiveequipmentforeyes,ears,feet,andhead isrecommended.

G009027

Figure10

1.Wearsafetyglasses

2.Wearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthemachineor leaveitunattended.

SettingtheParkingBrake

WARNING

Parkingbrakemaynotholdmachineparkedona slopeandcouldcausepersonalinjuryorproperty damage.

Donotparkonslopesunlesswheelsarechocked orblocked

G016994

Figure11

ReleasingtheParkingBrake

G016995

Figure12

OperatingtheMowerBlade ControlSwitch(PTO)

Thebladecontrolswitch(PTO)startsandstopsthemower bladesandanypoweredattachments.

EngagingtheBladeControlSwitch (PTO)

Note:Engagingthebladecontrolswitch(PTO)withthe

throttlepositionathalforlesswillcauseexcessivewearto thedrivebelts.

G008945

Figure13

DisengagingtheBladeControlSwitch (PTO)

G009174

Figure14

OperatingtheThrottle

ThethrottlecontrolcanbemovedbetweenFastandSlow positions(Figure15).

Alwaysusethefastpositionwhenturningonthemowerdeck withthebladecontrolswitch(PTO).

G008946

Figure15

OperatingtheChoke

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostarttheengine.

2.Pulluponthechokeknobtoengagethechokebefore usingtheignitionswitch(

Figure16).

3.Pushdownonthechoketodisengagethechokeafter theenginehasstarted(

Figure16).

G008959

Figure16

1.On2.Off

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition(Figure17). Whentheenginestarts,releasethekey .

Important:Donotengagethestarterformore than5secondsatatime.Iftheenginefailsto start,allowa15secondcool-downperiodbetween attempts.Failuretofollowtheseinstructionscan burnoutthestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthefuel systemhasbeencompletelywithoutfuel.

START

RUN

STOP

G008947

Figure17

2.Tostoptheengine,turntheignitionkeytothestop position.

UsingtheFuel-shutoffValve

Thefuel-shutoffvalveislocatedundertheseat.Movethe seatforwardtoaccessit.

Closethefuel-shutoffvalvefortransport,maintenance,and storage.

Ensurethatthefuel-shutoffvalveisopenwhenstartingthe engine.

G008948

Figure18

1.On2.Off

StartingandStoppingthe Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,sitontheseat andfastentheseatbelt.

2.Movethemotioncontrolstoneutrallockedposition.

3.Settheparkingbrake;refertoSettingtheParking Brake.

4.Movethebladecontrolswitch(PTO)totheOff position(Figure19).

5.MovethethrottlelevermidwaybetweentheSlowand Fastpositions.

g017006

Figure19

6.TurntheignitionkeytotheStartposition(Figure17). Whentheenginesstarts,releasethekey .

Important:Donotengagestarterformorethan5 secondsatatime.Iftheenginefailstostartallow a15secondcool-downperiodbetweenattempts. Failuretofollowtheseinstructionscanburnout thestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthefuel systemhasbeenwithoutfuelcompletely.

START

RUN

STOP

G008947

Figure20

1.Off3.Start

2.Run

StoppingtheEngine

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Lettheengineidleatslowthrottle(turtle)for60seconds beforeturningtheignitionswitchoff.

g017007

Figure21

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine,as fuelleakagemayoccur.Settheparkingbrakebefore transporting.Makesuretoremovethekeyasthefuel pumpmayrunandcausethebatterytolosecharge.

TheSafetyInterlockSystem

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventtheengine fromstartingunless:

•Theparkingbrakeisengaged.

•Thebladecontrolswitch(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked

position

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthelocked positionwiththeparkingbrakeengagedorifyourisefrom theseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.Whenthe componentisinthecorrectposition,atrianglewilllightup inthecorrespondingsquare.

G009181

Figure22

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethemachine eachtime.Ifthesafetysystemdoesnotoperateasdescribed below,haveanAuthorizedServiceDealerrepairthesafety systemimmediately.

1.Sittingontheseat,engagetheparkingbrakeandmove thebladecontrolswitch(PTO)toon.Trystartingthe engine;theengineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeandmove thebladecontrolswitch(PTO)tooff.Moveeither motioncontrollever(outofneutrallockedposition). Trystartingtheengine;theengineshouldnotcrank. Repeatforothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,movethe bladecontrolswitch(PTO)tooffandmovethemotion controlleverstoneutrallockposition.Nowstartthe engine.Whiletheengineisrunning,releasetheparking brake,engagethebladecontrolswitch(PTO)andrise slightlyfromtheseat;theengineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,movethe bladecontrolswitch(PTO)tooffandmovethemotion controlleverstoneutrallockposition.Nowstartthe engine.Whiletheengineisrunning,centereither motioncontrolandmove(forwardorreverse);the engineshouldstop.Repeatforothermotioncontrol.

5.Sittingontheseat,disengagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmovethe motioncontrolleverstoneutrallockposition.Try startingtheengine;theengineshouldnotcrank.

DrivingForwardorBackward

Thethrottlecontrolregulatestheenginespeedasmeasured inrpm(revolutionsperminute).Placethethrottlecontrolin thefastpositionforbestperformance.Alwaysoperateinthe fullthrottlepositionwhenmowing.

CAUTION

Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

UsingtheMotionControlLevers

Figure23

1.Motioncontrol lever-neutrallockposition

4.Backward

2.Center,unlockedposition5.Frontofmachine

3.Forward

DrivingForward

Note:Theenginewillkillifthetractioncontrolleversare

movedwiththeparkingbrakeengaged.

Tostop,pullthemotioncontrolleverstotheneutralposition.

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotioncontrollevers forward(Figure24).

G008952

Figure24

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrollevers rearward(Figure25).

G008953

Figure25

StoppingtheMachine

Tostopthemachine,movethetractioncontrolleversto neutralandmovetolockedposition,disengagethepower takeoff(bladecontrolswitch(PTO),andturntheignition keytooff.

Settheparkingbrakewhenyouleavethemachine;referto SettingtheParkingBrakeinOperation.Remembertoremove thekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhastwopositionsandisusedwiththe deck-liftpedal.Thereisalockpositionandaunlockposition forthetransportposition.Thetransportlockisusedwiththe deck-liftpedal.RefertoFigure26

Figure26

TransportLockPositions

1.Transportlock3.Unlockposition—doesnot lockthemowerdeckinto transportposition

2.Lockposition—mower

deckwilllockintotransport position

AdjustingtheHeight-of-cutPin

Theheightofcutisadjustedfrom25to140mm(1to 5-1/2inches)in6mm(1/4inch)incrementsbymovingthe clevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeck-liftpedalwithyourfootandraisethe mowerdecktothetransportposition(alsothe140mm (5-1/2inch)cutting-heightposition);referto

Figure27.

3.Toadjust,rotatethepin90degreesandremovethepin fromtheheight-of-cutbracket(Figure27).

4.Selectaholeintheheight-of-cutbracketcorresponding totheheightofcutdesired,andinsertthepin(Figure

27).

5.Pushonthedecklift,pullbackonthetransportlock, andslowlylowerthemowerdeck.

G017027

Figure27

1.Deck-liftpedal

3.Transportlock

2.Height-of-cutpin

AdjustingtheAnti-scalp Rollers

Wheneveryouchangetheheight-of-cut,itisrecommended toadjusttheheightoftheanti-scalprollers.

1.Disengagetheblade-controlswitch(PTO),movethe motion-controlleverstotheneutral-lockedposition, andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Adjusttheanti-scalprollersasshownin

,,and.

Figure28

1.Anti-scalproller4.Flangenut

2.Spacer

5.Bolt

3.Bushing

Figure29

1.Anti-scalproller3.Flangenut

2.Bushing4.Bolt

Figure30

1.Anti-scalproller4.Flangenut

2.Spacer

5.Bolt

3.Bushing

AdjustingtheFlowBafeCam Locks

Thisprocedureisapplicableonlytomachineswiththeow bafelocks.Certainmodelswillhavenutsandboltsin-place oftheowbafelocksandcanbeadjustedthesame.

Themowerdischargeowcanbeadjustedfordifferenttypes ofmowingconditions.Positionthecamlocksandbafeto givethebestqualityofcut.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Toadjustthecamlocks,swingtheleveruptoloosen thecamlock(Figure31).

4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow .

5.Swingtheleverbackovertotightenthebafeandcam locks(

Figure31).

6.Ifthecamlocksdonotlockthebafeintoplaceorit istootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilthedesiredlocking pressureisachieved.

G008961

Figure31

1.Unlocklever

3.Positionthebafe

2.Rotatethecamlockto increaseordecrease lockingpressure

4.Locklever

PositioningtheFlowBafe

Thefollowingguresareonlyrecommendationsforuse. Adjustmentswillvarybygrasstype,moisturecontent,and heightofgrass.

Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggesteduseforthis positionisasfollows:

•Useforshort,lightgrassmowingconditions.

•Useindryconditions.

•Useforsmallergrassclippings.

•Usetopropelgrassclippingsfartherawayfromthe

mower.

Figure32

PositionB

Usethispositionwhenbagging.Alwaysalignitwiththe bloweropening.

Figure33

PositionC

Thisisthefullopenposition.Thesuggesteduseforthis positionisasfollows:

•Useintall,densegrass-mowingconditions.

•Useinwetconditions.

•Usetolowertheenginepowerconsumption.

•Usetoallowincreasedgroundspeedinheavyconditions.

•ThispositionoffersbenetssimilartothoseoftheT oro

SFSmower.

Figure34

PositioningtheSeat

Theseatcanmoveforwardandbackward.Positiontheseat whereyouhavethebestcontrolofthemachineandaremost comfortable.

Toadjust,movetheleversidewaystounlockseat(Figure35).

G008962

Figure35

UsingtheDriveWheelRelease Valves

WARNING

Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury.

Stoptheengine,removethekey,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.Touchingahotengineorhydraulicdrive unitscancausesevereburns.

Allowtheengineandhydraulicdriveunitstocool completelybeforeaccessingthedrivewheelrelease valves.

Thedrivewheelreleasevalvesarelocatedinthebackofeach hydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefullyhorizontal positionwhenoperatingthemachineorseveredamagetothe hydraulicsystemcanoccur.

1.DisengagethePTO(bladecontrolswitch)andturnthe ignitionkeytooff.Movetheleverstoneutrallocked positionandapplyparkingbrake.Removethekey.

2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthepump enablingthewheelstoturn(Figure36).

3.Disengageparkingbrakebeforepushing.

g015123

Figure36

1.Verticaltopushthe machine

2.Horizontaltorunthe machine

4.Rotatethereleasevalvelevershorizontallytorunthe machine(Figure36).

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

DANGER

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

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

•Neverputyourhandsorfeetunderthemower.

•Nevertrytoclearthedischargeareaormower bladesunlessyoumovethepowertakeoff (blade-controlswitch/PTO)totheoffposition, rotatetheignitionkeytooffandremovethekey.

•Makesurethatthegrassdeectorisinthedown position.

LoadingtheMachine

Useextremecautionwhenloadingthemachineontoatrailer ortruck.Onefull-widthrampthatiswideenoughtoextend beyondthereartiresisrecommendedinsteadofindividual rampsforeachsideofthemachine(Figure37).Thelower rearsectionofthemachineframeextendsbackbetweenthe rearwheelsandservesasastopfortippingbackward.Having afull-widthrampprovidesasurfacefortheframemembers tocontactifthemachinestartstotipbackward.Ifitisnot possibletouseonefull-widthramp,useenoughindividual rampstosimulateafull-widthcontinuousramp.

Therampshouldbelongenoughsothattheanglesdonot exceed15degrees(Figure37).Asteeperanglemaycause mowercomponentstogetcaughtasthemachinemovesfrom theramptothetrailerortruck.Steeperanglesmayalsocause themachinetotipbackward.Ifloadingonornearaslope, positionthetrailerortrucksothatitisonthedownside oftheslopeandtherampextendsuptheslope.Thiswill minimizetherampangle.Thetrailerortruckshouldbeas levelaspossible.

Important:Donotattempttoturnthemachinewhile ontheramp;youmaylosecontrolanddriveofftheside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausethemachinetotipbackward.

WARNING

Loadingamachineontoatrailerortruckincreases thepossibilityofbackwardtip-overandcouldcause seriousinjuryordeath.

•Useextremecautionwhenoperatingamachine onaramp.

•EnsurethattheROPSisintheuppositionwhile usingtheseatbeltwhenloadingthemachine. EnsurethattheROPSwillclearthetopofan enclosedtrailer.

•Useonlyasingle,full-widthramp;donotuse individualrampsforeachsideofthemachine.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurfacewider thanthemachine.

•Donotexceeda15degreeanglebetweenthe rampandthegroundorbetweentherampand thetrailerortruck.

•Avoidsuddenaccelerationwhiledrivingthe machineuparamp,toavoidtippingbackward.

•Avoidsuddendecelerationwhilebacking themachinedownaramp,toavoidtipping backward.

Figure37

1.Trailer3.Notgreaterthan 15degrees

2.Full-widthramp4.Full-widthramp—side view

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthemachine. Ensurethatthetrailerortruckhasallnecessarybrakes, lighting,andmarkingasrequiredbylaw.Pleasecarefullyread allthesafetyinstructions.Knowingthisinformationcould helpyou,yourfamily,pets,orbystandersavoidinjury.

WARNING

Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow-moving vehicleemblemisdangerousandcanleadto accidentscausingpersonalinjury.

Donotdrivethemachineonapublicstreetor roadway.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicleand connectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

5.Usethemetaltie-downloopsonthemachineto securelyfastenthemachinetothetrailerortruckwith straps,chains,cable,orropes(

Figure38).

Figure38

1.Tie-downloops

OperatingTips

FastThrottleSetting

Forbestmowingandmaximumaircirculation,operate theengineatthefastthrottleposition.Airisrequiredto thoroughlycutgrassclippings,sodonotsettheheight-of-cut solowastototallysurroundthemowerbyuncutgrass. Alwaystrytohaveonesideofthemowerfreefromuncut grass,whichallowsairtobedrawnintothemower.

CuttingaLawnfortheFirstTime

Cutgrassslightlylongerthannormaltoensurethecutting heightofthemowerdoesnotscalpanyunevenground. However,thecuttingheightusedinthepastisgenerallythe bestonetouse.Whencuttinggrasslongerthansixinchestall, youmaywanttocutthelawntwicetoensureanacceptable qualityofcut.

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade.Cutting morethanthatisnotrecommendedunlessgrassissparse,or itislatefallwhengrassgrowsmoreslowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhichenhances decompositionandfertilization.

MowatCorrectIntervals

Normally,moweveryfourdays.Butremember,grassgrows atdifferentratesatdifferenttimes.Sotomaintainthesame cuttingheight,whichisagoodpractice,mowmoreoftenin earlyspring.Asthegrassgrowthrateslowsinmidsummer, mowlessfrequently .Ifyoucannotmowforanextended period,rstmowatahighcuttingheight;thenmowagain twodayslateratalowerheightsetting.

CuttingSpeed

Toimprovecutquality ,useaslowergroundspeedincertain conditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthemower youpreviouslyused,raisethecuttingheighttoensurethat uneventurfisnotcuttooshort.

LongGrass

Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raisethe

cuttingheighthigherthanusualandcutthegrassatthis setting.Thencutthegrassagainusingthelower,normal setting.

WhenStopping

Ifyoumuststoptheforwardmotionofthemachinewhile mowing,aclumpofgrassclippingsmaydropontoyourlawn. Toavoidthis,moveontoapreviouslycutareawiththeblades engaged.

KeeptheUndersideoftheMowerClean

Cleanclippingsanddirtfromtheundersideofthemower aftereachuse.Ifgrassanddirtbuildupinsidethemower, cuttingqualitywilleventuallybecomeunsatisfactory.

BladeMaintenance

Maintainasharpbladethroughoutthecuttingseasonbecause asharpbladecutscleanlywithouttearingorshreddingthe grassblades.Tearingandshreddingturnsgrassbrownat theedges,whichslowsgrowthandincreasesthechanceof disease.Checkthecutterbladesdailyforsharpness,andfor anywearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn,replaceit immediatelywithagenuineTOROreplacementblade.

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

MaintenanceProcedure

Aftertherst8hours

•Changetheengineoil.

Aftertherst100hours

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Checktheparkbrakeadjustment.

Aftertherst250hours

•Changethehydraulicltersandhydraulicoilwhenusinganytypeofoil.

Beforeeachuseordaily

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunits.

•Checkthemowerblades.

•Cleanthemowerdeck.

Every50hours

•Greasethemowerdeckspindlesandidlerarm.

•Checkthesparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

Every100hours

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Checkandgapthesparkplugs.

•Checkandcleanenginecoolingnsandshrouds.

Every200hours

•Changetheengineoillter.

Every250hours

•Replacetheprimaryairlter.

•Checkthesecondaryairlter.

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

Every500hours

•Replacethesecondaryairlter.

•Replacethefuellter.(moreoftenindirtyordustyconditions).

•Checkthewheellugnuttorque.

•Checkthewheelhubslotted-nuttorque.

•Adjustthecasterpivotbearing.

•Checktheparkbrakeadjustment.

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

Monthly

•Checkthebattery .

Yearly

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Lubricatethecasterwheelhubs

Yearlyorbeforestorage

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy .

GreaseType:#2general-purposelithium-basedor molybdenum-basedgrease

HowtoGrease

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Cleanthegreasettingswitharag.Makesuretoscrape anypaintoffthefrontofthetting(s).

4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutofthe bearings.

5.Wipeupanyexcessgrease.

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every100hours

Deckliftpivots.

G017028

Figure39

WheretoGreasetheMower

ServiceInterval:Every50hours—Greasethemowerdeck

spindlesandidlerarm.

Yearly—Greasethepumpbeltidlerarm.

Yearly—Greasethefrontcasterpivots(moreoftenin dirtyordustyconditions).

Yearly—Repackthefrontcasterwheelbearings(more oftenindirtyordustyconditions).

Important:Makesurethatthecuttingunitspindlesare fullofgreaseweekly.

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

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(

Figure40).

4.Greasethettingsonthetopofthe3spindlebearings untilgreasecomesout(Figure40).

G009029

Figure40

5.Greasethedrivebeltidlerarm(Figure40).

Figure41

6.Removethedustcapandadjustthecasterpivots.Keep thedustcapoffuntilgreasingiscomplete.Referto AdjustingtheCasterPivotBearinginMaintenance.

7.Removethehexplug.Threadagreasettingintothe hole.

8.Pumpgreaseintothettinguntilitoozesoutaround thetopbearing.

9.Removethegreasettingfromthehole.Installthehex pluganddustcap(

Figure42).

Figure42

LubricatingtheCasterWheel Hubs

ServiceInterval:Yearly

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.

Figure43

1.Sealguard2.Spacernutwithwrench ats

2.Raisethefrontofthemachineup,andsupportitwith jackstands(orequivalentsupport)justhighenoughto allowthefrontwheelstoturnfreely.

3.Removethecasterwheelfromthecasterforks.

4.Removethesealguardsfromthewheelhub.

5.Removeoneofthespacernutsfromtheaxleassembly inthecasterwheel.Notethatthread-lockingadhesive hasbeenappliedtolockthespacernutstotheaxle. Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly .

6.Pryoutseals,andinspectthebearingsforwearor damageandreplacethemifnecessary.

7.Packthebearingswithageneral-purposegrease.

8.Insertonebearing,onenewsealintothewheel.

Note:Thesealsmustbereplaced.

9.Iftheaxleassemblyhashadbothspacernutsremoved (orbrokenloose),applyathread-lockingadhesive toonespacernutandthreaditontotheaxlewith thewrenchatsfacingoutward.Donotthreadthe spacernutallthewayontotheendoftheaxle.Leave approximately3mm(1/8inch)fromtheoutersurface ofthespacernuttotheendoftheaxleinsidethenut.

10.Inserttheassemblednutandaxleintothewheelonthe sideofthewheelwiththenewsealandbearing.

11.Withtheopenendofthewheelfacingup,llthearea insidethewheelaroundtheaxlefullofgeneral-purpose grease.

12.Insertthesecondbearingandanewsealintothewheel.

13.Applyathread-lockingadhesivetothe2ndspacernut andthreaditontotheaxlewiththewrenchatsfacing outward.

14.Torquethenutto8to9N-m(75to80in-lb),loosenit, thentorqueitto2to3N-m(20to25in-lb).Makesure thattheaxledoesnotextendbeyondeithernut.

15.Installthesealguardsoverthewheelhubandinsert thewheelintothecasterfork.Installthecasterbolt andtightenthenutfully.

16.Removethejackstands.

Important:Topreventsealandbearingdamage,check thebearingadjustmentoften.Spinthecasterwheel. Thewheelshouldnotspinfreely(morethan1or2 revolutions)orhaveanysideplay.Ifthewheelspins freely,adjustthetorqueonspacernutuntilthereisa slightamountofdrag.Applythread-lockingadhesive.

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacetheprimaryair

lter.

Every250hours—Checkthesecondaryairlter.

Every500hours—Replacethesecondaryairlter.

Note:Servicetheaircleanermorefrequentlyifoperating conditionsareextremelydustyorsandy.

RemovingtheFilters

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Pushdowntoreleasetheretainingclampsontheair cleanerandpulltheaircleanercoveroffoftheair cleanerbody(

Figure44).

4.Cleantheinsideoftheaircleanercoverwith compressedair.

5.Gentlyslidetheprimarylteroutoftheaircleaner body(Figure44).Avoidknockingthelterintothe sideofthebody.

6.Removethesecondarylteronlyifyouintendto replaceit.

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

7.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutsideof thelter.Holesinthelterwillappearasbrightspots. Ifthelterisdamageddiscardit.

Figure44

1.Aircleanerclamps

3.Primaryairlter

2.Aircleanercover

4.Secondaryairlter

ServicingthePrimaryFilter

1.Donotcleanthepaperlter,replaceit(Figure44).

2.Inspecttheelementfortears,anoilylm,ordamageto therubberseal.

3.Replacethepaperelementifitisdamaged.

ServicingtheSecondaryFilter

Donotcleanthesecondarylter,replaceit.

Important:Neverattempttocleanthesecondarylter. Ifthesecondarylterisdirty,thentheprimarylteris damagedandyoushouldreplacebothlters.

InstallingtheFilters

Important:T opreventenginedamage,alwaysoperate

theenginewithbothairltersandcoverinstalled.

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

2.Ifthesecondarylterisbeingreplaced,carefullyslide itintothelterbody(Figure44).

3.Carefullyslidetheprimarylteroverthesecondary lter(Figure44).Ensurethatitisfullyseatedby pushingontheouterrimofthelterwhileinstallingit.

Important:Donotpressonthesoftinsidearea ofthelter.

4.Installtheaircleanercoverwiththebreathercapdown androtatesotheretainingclampslockthecoverin place(

Figure44).

ServicingtheEngineOil

OilType:Detergentoil(APIserviceSG,SH,SJ,orSL)

CrankcaseCapacity:withalterchange,2.1L(2.2USqt);

withoutalterchange,1.8L(1.9USqt)

Viscosity:Seethetablebelow.

Figure45

Note:Useofmulti-gradeoils(5W-20,10W -30,or10W-40)

willincreaseoilconsumption.Checktheoillevelmore frequentlywhenusingthem.

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donotrun enginewithoilbelowthelowmarkbecausetheengine maybedamaged.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure46).

G008804

G008792

Figure46

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirtyordusty conditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothattherearisslightlylowerthan thefronttoensuretheoildrainscompletely .

2.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure47).

G008804

G008793

Figure47

4.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloilto bringittotheFullmark(Figure48).

G008796

Figure48

5.Starttheengineanddrivetoaatarea.Checktheoil levelagain.

ChangingtheEngineOilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequentlywhen operatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Changetheengineoillter(

Figure49).

G008804

G008748

3/4

Figure49

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

3.Fillthecrankcasewiththepropertypeofnewoil;refer toChangingtheOil.

ServicingtheSparkPlugs

ServiceInterval:Every100hours

Makesurethattheairgapbetweenthecenterelectrodeand thesideelectrodeiscorrectbeforeinstallingeachsparkplug. Useaspark-plugwrenchforremovingandinstallingthespark plugsandagappingtool/feelergaugetocheckandadjustthe airgap.Installnewsparkplugsifnecessary.

Type:NGK

BPR4ESorequivalent

AirGap:0.76mm(0.030inch)

RemovingtheSparkPlugs

Important:Thefastenersonthecoversofthismachine

aredesignedtoremainonthecoverafterremoval. Loosenallofthefastenersoneachcoverafewturnsso thatthecoverisloosebutstillattached,thengoback andloosenthemuntilthecovercomesfree.Thiswill preventyoufromaccidentallystrippingtheboltsfree oftheretainers.

1.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

2.DisengagethePTO,movethemotion-controlleversto theneutral-lockedposition,andsettheparkingbrake.

3.Removethehydraulic-unitshroudandthe2bolts attachedtoit(

Figure50).Thisgivesyouaccesstothe

frontsparkplug.

G012432

2 1 2

Figure50

1.Hydraulic-unitshroud2.Loosenthese2bolts

4.Removethesparkplugs.

G008803

Figure51

5.Installtheleft-handhydraulic-unitshroud(Figure50).

CheckingtheSparkPlugs

Important:Nevercleanthesparkplug(s).Always

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

Ifyouseelightbrownorgrayontheinsulator,theengineis operatingproperly.Ablackcoatingontheinsulatorusually meansthattheaircleanerisdirty.

Setthegapto0.76mm(0.030inch).

G008794

Figure52

InstallingtheSparkPlugs

Tightenthesparkplugsto24.4to29.8N-m(18to22ft-lb).

Figure53

CheckingtheSparkArrester (ifequipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresultin personalinjuryorpropertydamage.

Donotfuelorruntheengineunlessthespark arresterisinstalled.

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.

2.Waitforthemufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacethearrester.

4.Ifpluggingofthescreenisobserved,removethe arresterandshakeanylooseparticlesoutofthe arrester,andcleanthescreenwithawirebrush(soakit insolventifnecessary).Installthesparkarresteronthe exhaustoutlet.

FuelSystem Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every500hours/Yearly(whichevercomes

rst)(moreoftenindirtyordusty conditions).

Thefuellterislocatedneartheengineonthefrontorrear sideoftheengine.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Allowthemachinetocooldown.

4.Closethefuel-shutoffvalveundertheseat(

Figure54).

G008963

12

Figure54

1.Fuellter

3.Fuelline

2.Hoseclamp

5.Squeezetheendsofthehoseclampstogetherandslide themawayfromthelter(Figure54).

6.Removethelterfromthefuellines.

7.Installanewlterandmovethehoseclampscloseto thelter(Figure54).

8.Openthefuel-shutoffvalve.

Important:Installthefuellinehosesandsecurewith plastictiesthesameastheywereoriginallyinstalledat thefactory,tokeepthefuellineawayfromcomponents thatcouldcausefuellinedamage.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankandservices anycomponentsofthefuelsystem.

ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

W ash hands after handling .

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygasestoexplode,resulting inpersonalinjury.

•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

WARNING

Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygasestoexplode,resultingin personalinjury.

•Alwaysdisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.

•Alwaysconnectthepositive(red)batterycable beforereconnectingthenegative(black)cable.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Firstdisconnectthenegativebatterycable(black)from thenegative(-)(black)batteryterminal(

Figure55).

4.Slidetheredterminalbootoffthepositive(red)battery terminalandremovethepositive(+)(red)batterycable (Figure55).

5.Removethewingnutsecuringthebatteryclamp (

Figure55).

6.Removetheclamp(Figure55).

7.Removethebattery.

g014731

Figure55

1.Removethewingnutand clamp

3.Removethepositive batterycable

2.Removethenegative batterycablebeforethe positive

4.Removebattery

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure55).

2.First,installthepositive(red)batterycabletopositive (+)batteryterminal.

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

4.Securethecableswith2bolts,2washers,and2locknuts (

Figure55).

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.Installtheclampandsecureitwiththewingnut(

Figure

55).

ChargingtheBattery

WARNING

Chargingthebatteryproducesgasesthatcan explode.

Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.

Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportantto preventbatterydamagewhenthetemperatureisbelow 0°C(32°F).

1.Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.

2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet;thendisconnectthecharger leadsfromthebatteryposts(Figure56).

3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected;electricaldamagemayoccur.

Figure56

1.Positivebatterypost

3.Red(+)chargerlead

2.Negativebatterypost

4.Black(-)chargerlead

ServicingtheFuses

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

1.Thefusesarelocatedonrighthandconsolenextto theseat(Figure57).

2.Toreplacethefuses,pulloutonthefusetoremoveit.

3.Installanewfuse(

Figure57).

Figure57

1.Optional accesory—15amp

4.Main—25amp

2.Charge—25amp5.Console

3.PTO—10amp

DriveSystem Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproperoperation ofretractorandbuckle.Replacebeforeoperatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

WARNING

Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraisedlockedpositionandusethe seatbelt.

Ensuretheseatissecuredtothemachine.

Checkthatboththemountinghardwareandtheknobsare ingoodworkingcondition.Makesuretheknobsarefully engagedwiththeROPSintheraisedposition.Theupper hoopoftherollbarmayneedtobepushedforwardorpulled rearwardtogetbothknobsfullyengaged.

Figure58

1.ROPSknob(locked position)

3.Rollbarintheupright position

2.PullROPSknoboutand rotate90degreesto changerollbarposition

4.Rollbarinthefolded position

AdjustingtheTracking

1.Disengagethebladecontrolswitch(PTO).

2.Drivetoanopenatarea,movethemotioncontrol leverstotheneutrallockedposition.

3.Movethethrottlemidwaybetweenfastandslow.

4.Movebothmotioncontrolleversallthewayforward untiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust theleftstopplaterearwardontheleftT-slotuntilthe machinetracksstraight(Figure59).

7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplaterearwardontherightT-slotuntilthe machinetracksstraight(Figure59).

8.Tightenthestopplate(Figure59).

Figure59

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat90kPa(13psi). Uneventirepressurecancauseunevencut.Checkthetires whentheyarecold,togetthemostaccuratepressurereading.

Note:Thefronttiresaresemi-pneumatictiresanddonot requireairpressuremaintenance.

Figure60

CheckingtheWheelLugNuts

Checkandtorquethewheellugnutsto122to129N-m(90 to95ft-lb).

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

Checkandensurethatthetorqueoftheslottednutis286to 352N-m(211to260ft-lb).

Note:Donotuseanti-seizeonwheelhub.

Figure61

1.Slottednut

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichevercomes

rst)

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removethedustcapfromcasterandtightenlocknut (

Figure62).

4.Tightenthelocknutuntilthespringwashersareatand thenbackoffa1/4turntoproperlysetthepre-loadon thebearings(Figure62).

Important:Makesurethespringwashersare installedcorrectlyasshowninFigure62.

5.Installthedustcap(Figure62).

Figure62

1.SpringWashers3.DustCap

2.LockNut

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwithclutchesthat containabrakeshim.Whentheclutchbrakehasworntothe pointwheretheclutchnolongerengagesconsistently ,the shimcanberemovedtoextendtheclutchlife.

Figure63

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.Allow themachinetocoolcompletelybeforestartingthese instructions.

2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.

Figure64

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairasnecessary.

4.Verifythat12Vispresentattheclutchconnectorwhen thePTOswitchisengaged.

5.Measurethegapbetweentherotorandthearmature. Ifthegapisgreaterthan1mm(0.04inch),proceed withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

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

Figure65

1.Brakemountingbolt

B.Usingneedle-nosepliers,orbyhand,takeholdof

thetabandremovetheshim.

Note:Donotdiscardtheshimuntilproper clutchfunctionhasbeenconrmed.

Figure66

1.Shim

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake spacers.

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

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

E.Usinga0.010inchthickfeelergauge,verifythat

agapispresentbetweentherotorandarmature faceonbothsidesofthebrakepoleasshown. (Duetothewaytherotorandarmaturefaces wear(peaksandvalleys)itissometimesdifcult tomeasurethetruegap.)

Figure67

1.Feelergauge

Figure68

1.Feelergauge

•Ifthegapislessthan0.010inch,thenreinstall

theshimandreferencetheTroubleshooting section.

•Ifthegapissufcient,proceedtothesafety

checkinstep

F.Performthefollowingsafetycheck:

i.Sitontheseatandstarttheengine.

ii.Makesurethatthebladesdonotengage

withthePTOswitchedoffandtheclutch disengaged.

Iftheclutchdoesnotdisengage,installthe shimandreferencetheTroubleshooting section.

iii.EngageanddisengagethePTOswitch10

consecutivetimestoensurethattheclutch isfunctioningproperly .Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

CoolingSystem Maintenance

CleaningtheEngineScreen andEngineOilCooler

ServiceInterval:Beforeeachuseordaily

Removeanybuildupofgrass,dirt,orotherdebrisfromthe oilcooler(Figure69).

G008804

Figure69

Beforeeachuseremoveanybuildupofgrass,dirt,or otherdebrisfromtheenginescreen.Thiswillhelpensure adequatecoolingandcorrectenginespeedandwillreduce thepossibilityofoverheatingandmechanicaldamagetothe engine(Figure70).

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every100hours/Yearly(whichevercomes

rst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removetheairintakescreen,recoilstarterandfan housing(Figure70).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing (

Figure70).

Figure70

1.Engineguard4.Fanhousing

2.Engineairintakescreen

5.Screw

3.Bolt

CheckingandCleaningthe HydraulicUnits

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Movetheseatforward.

4.Cleanthedebrisandgrassfromthehydraulicunits (

Figure71).

5.Positiontheseat.

g0151 17

Figure71

1.Hydraulicunits

BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurethatthebrakeisadjustedproperly.This proceduremustbefollowedaftertherst100hoursorwhen abrakecomponenthasbeenremovedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop,and removethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

DANGER

Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury.

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothereleased position.RefertotheUsingtheDriveWheel ReleaseV alvessectioninOperation.

8.Measuretheoveralllengthofthecompressionspring. Thecorrectlengthshouldbebetween3.8and4.0 cm(1-1/2and1-9/16inches).Ifthespringlengthis withinthisrange,noadjustmentisneeded.Ifitisnot, proceedtostep9.

9.Holdthethreadedrodendwithatoolandadjustthe locknutuntilthespringlengthisbetween3.8and4.0 cm(1-1/2and1-9/16inches);refertoFigure72.Do notallowthecabletoturnwhenthenutsarebeing loosened.

Figure72

Left-handbrakeshown

1.Cableanchor5.Caliper

2.Holdthreadedrodhere

6.Compressionspring

3.Measure7.Threadedrod

4.Locknut8.Hub

10.Releasetheparkingbrake.Turnthewheelhubbyhand inbothdirectionsrelativetothecaliper;nodragofthe caliperpadonthewheelhubisdesired.

11.Ifthereisnomovementbetweenthehubandthe caliper,thenrepeattheadjustment(drivereleasevalves mustbeinthereleasedpositiononthehydros).

12.Afteradjustingthebrakesonbothsidesofthemachine, cyclethebrakehandleaminimumof6timestoallow thecabletoseatintothesheathandmountingtabs.

13.Checkthespringlength;engagetheparkingbrakeand repeatsteps8through11ifthelengthisnotinthe correctrange.

14.Rotatethedrivewheelreleasehandletotheoperating position.RefertotheUsingtheDriveWheel ReleaseV alvessectioninOperation.

15.Installthereartiresandtorquethelugnutsbetween 122and129N-m(90and95ft-lb).

16.Removethejackstands.

BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating,blades slippingwhencuttinggrass,frayedbeltedges,burnmarks, andcracks.Thesearesignsofawornmowerbelt;replacethe mowerbeltifanyoftheseconditionsareevident.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarks,andcracksare signsofawornmowerbelt.Replacethemowerbeltifanyof theseconditionsareevident.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Lowerthemowertothe76mm(3inch)heightofcut.

4.Removethebeltcovers(Figure73).

G009036

Figure73

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(Figure74).

6.Removethebeltfromthemowerdeckpulleys.

7.Removethebeltguideonthespring-loadedidlerarm showninFigure74.

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysandthe clutchpulleyundertheengine(Figure74).

Figure74

1.Clutchpulley5.Squareholeintheidler armfortheratchet

2.Mowerbelt

6.Idlergreasetting

3.Spring-loadedidlerpulley

7.Beltguide

4.Ratchet

10.InstallthebeltguideontheidlerarmshowninFigure

74.

11.Usingtheratchetinthesquarehole,installtheidler spring(Figure74).

Makesurethatthespringendsareseatedintheanchor grooves.

12.Installthebeltcovers(Figure75).

Figure75

1.Positionthebeltcover3.Ensurethatthetabis underthemetalcatch

2.Slidebeltcoverunderthe

sidecatches

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.

4.Raisethemachineandsupportitwithjackstands (Figure76).

Figure76

1.Idlerpulley

5.Lefthandhydraulicpump pulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump pulley

5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure76).

6.Unhooktheidlerspringfromtheframe(Figure76).

7.Removethebeltfromthehydraulicunitdrivepulleys andtheenginepulley

8.Installthenewbeltaroundenginepulleyandthetwo drivepulleys.

9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(Figure76).

10.Installthemowerbelt.RefertoReplacingtheMower Belt.

ControlsSystem Maintenance

AdjustingtheControlHandle Position

Therearetwoheightpositionsforthecontrollevers;highand low .Removetheboltstoadjusttheheightfortheoperator.

1.DisengagethePTO,movethemotioncontrolleversto theneutrallockedposition,andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Loosentheboltsandangenutsinstalledinthelevers (Figure77).

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslidethem untiltheyarealigned,thentightenthebolts(Figure78).

Figure77

1.Bolt

3.Controllever

2.Handle4.Nut

Figure78

AdjustingtheMotionControl Linkage

Locatedoneithersideofthefueltank,belowtheseatare thepumpcontrollinkages.Rotatingthepumplinkagewitha 1/2inchwrenchallowsnetuningadjustmentssothatthe machinedoesnotmoveinneutral.Anyadjustmentsshould bemadeforneutralpositioningonly .

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearofrotating componentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdecktothe ground.

2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely.

3.Removetheelectricalconnectionfromtheseatsafety switch,locatedunderthebottomcushionoftheseat. Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrosstheterminals intheconnectorofthemainwiringharness.

5.Startengine.Brakemustbeengagedandmotion

controlleversouttostartengine.Operatordoes nothavetobeintheseatbecauseofthejumper wirebeingused.Runengineatfullthrottleand

releasebrake.

6.Runtheunitatleast5minuteswiththedriveleversat fullforwardspeedtobringhydraulicoiluptooperating temperature.

Note:Themotioncontrolleverneedstobeinneutral whilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsbyrotating thedoublenutsontherodintheappropriatedirection untilthewheelsslightlycreepinreverse(

Figure79). Movethemotioncontrolleverstothereverseposition andwhileapplyingslightpressuretotheleverallow thereverseindicatorspringstobringtheleversback toneutral.Thewheelsmuststopturningorslightly creepinreverse.

g014943

Figure79

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwireharness andplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutralwith theparkbrakesdisengaged.

AdjustingtheMotionControl Damper

Thetopdampermountingboltcanbeadjustedtoobtaina moredesiredmotioncontrolleverresistance.SeeFigure80 formountingoptions.

Figure80

Right-handmotioncontrolshown

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

2.Mostresistance(rmestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Leastresistance(softestfeel)

AdjustingtheMotionControl NeutralLockPivot

Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittotheneutral lockposition.SeeFigure81foradjustmentoptions.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenthejamnut.

Figure81

1.Flangednut2.Jamnut

HydraulicSystem Maintenance

ServicingtheHydraulic System

HydraulicOilType:Toro

HYPR-OIL

™

500hydraulicoil

orMobil

115W-50.

Important:Useoilspecied.Otheruidscouldcause systemdamage.

EachHydraulicSystemOilCapacity:1.5L(1.59USqt)

persidewithlterchange

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulicoil

level.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotioncontrolleversto theneutrallockedpositionandsettheparkingbrake.

3.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

4.Allowtheengineandthehydraulicsystemtocoolfor 10minutes.

Note:Theoillevelonthedipstickwillbeincorrectif theoilischeckedwhenthemachineishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofthe hydraulic-systemreservoirs(Figure82).

7.Removeonedipstickfromthehydraulicreservoir (

Figure82).

8.Wipethedipstickoffandthreadthedipstickintothe reservoir.

9.Removethedipstickandlookattheend(Figure82). Iftheoillevelisattheaddmark,slowlypouronly enoughoilintothehydraulicreservoirtoraisethelevel tothefullorHline.

Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewiththeoilbelowtheaddmark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

G015459

Figure82

Eitherdipstickwillbeusedinthemachine

1.Full3.H—meanshighlevel

2.Add4.Dipsticklocationsunder seat

WARNING

Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistype ofinjury.Gangrenemayresultifthisis notdone.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

•Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

ReplacingtheHydraulicFiltersand HydraulicOil

ServiceInterval:Aftertherst250hours—Changethe

hydraulicltersandhydraulicoilwhen usinganytypeofoil.

Every250hours—Changethehydraulicltersand hydraulicoilwhenusingMobil

1oil(moreoftenin

dirtyordustyconditions).

Every500hours—Changethehydraulicltersand hydraulicoilwhenusingToro

HYPR-OIL

™

500

hydraulicoil(moreoftenindirtyordustyconditions).

Toreplacethehydraulicoil,theltersneedtoberemoved. Replacebothatthesametime.Refertotheoilspecications underServicingtheHydraulicSystemforthecorrectoil.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisethemachineandsupportitwithjackstands (

Figure83).

Figure83

1.Jackstands

4.Removeboththemowerbeltandthepumpdrivebelt. Thiswillpreventoilgettingonthebelts.RefertoBelts intheMaintenanceSection.

5.Placeadrainpanunderthelter,removetheoldlter andwipethesurfaceclean(

Figure84).

G008968

Figure84

BottomViewofMachine

1.Filterlocations

2.Hydrauliclter

6.Applyathincoatofhydraulicoiltotherubbergasket onthereplacementlter(Figure84).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine(Figure

83).

10.Addoiltothehydraulicreservoirandcheckforany leaks.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwominutesto purgeairfromthesystem.Stoptheengineandcheck forleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Donot overll.

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethatthemowerdeckisleveledbefore

matchingtheheightofcut(HOC).

1.Positionthemachineonaatsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

4.Checkthetirepressureofthedrivetires.Ifneeded, adjustthepressureto90kPa(13psi)

5.Positionthemowertothe76mm(3inch)height-of-cut position.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper inationpressurefortiresis90kPa(13psi).Adjust ifnecessary.

4.Positionthetransportlockinthelatchingposition.

5.Pushthedeckliftpedalallthewayforwardandthe deckwilllatchatthe14cm(5-1/2inch)transport position(

Figure85).

G017027

Figure85

1.Deck-liftpedal

3.Transportlock

2.Height-of-cutpin

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

7.Releasethetransportlockandallowthedecktolower tothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA).The measurementshouldread7.6mm(3inches);referto Figure86.

Figure86

1.7.6cm(3inches)atAis correct

3.Measureherefromthe bladetiptohardsurface

2.8.3cm(3-1/4inches)atB iscorrect

4.MeasureatAandBon bothsides

10.Ifneeded,loosentheangedlocknutonthesideofthe yokeandthejamnutontop.Fine-tunetheadjuster screwbyturningittoget7.6mm(3inch)height (Figure87).

Toincreasetheheight,turntheadjusterscrew clockwise;todecreasetheheight,turnit counterclockwise.

Figure87

1.Flangedlocknut3.Jamnut

2.Adjusterscrew4.Y oke

11.Ifthefrontdecklinksdonothaveenoughadjustment toachieveaccuratecutheight,thesinglepoint adjustmentcanbeutilizedtogainmoreadjustment.

12.Toadjustthesinglepointsystem,loosenthetwobolts atthebottomoftheheight-of-cutplate.Referto Figure88.

g017029

Figure88

1.Boltsatthebottomoftheheight-of-cutplate

13.Ifthedeckistoolow ,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.Ifthedeckis toohigh,loosenthesinglepointadjustmentboltby rotatingitcounterclockwise(Figure89).

Note:Loosenortightenthesinglepointadjustment boltenoughtomovetheheight-of-cutplatemounting boltsatleast1/3thelengthoftheavailabletravel intheirslots.Thiswillregainsomeup-and-down adjustmentoneachofthe4decklinks.

g017036

Figure89

1.Singlepointadjustmentbolt

14.Tightenthe2boltsatthebottomoftheheight-of-cut plate(Figure88).Torquethemto37to45N-m(27 to33ft-lb).

Note:Inmostconditions,thebackbladetipshould beadjusted6.4mm(1/4inch)higherthanthefront.

15.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(PostionB).The measurementshouldread8.3cm(3-1/4inches);refer toFigure86.

16.Fine-tunetheadjusterscrewbyturningittoget8.3 mm(3-1/4inches)height(Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecreasetheheight,turnthenut counterclockwise.

17.Measureuntilall4sidesarethecorrectheight.Tighten allthejamnutsonthedeck-liftarmassemblies.

18.Lowerthedischargechute.

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason,because sharpbladescutcleanlywithouttearingorshreddingthegrass blades.Tearingandshreddingturnsgrassbrownattheedges, whichslowsgrowthandincreasesthechanceofdisease.

Checkthecutterbladesdailyforsharpness,andforany wearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn,replace itimmediatelywithagenuineT ororeplacementblade.For convenientsharpeningandreplacement,youmaywantto keepextrabladesonhand.

DANGER

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

BeforeInspectingorServicingthe Blades

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

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(

Figure90).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea(Figure

90).Ifyounoticeanydamage,wear,oraslotforming inthisarea(Figure90),immediatelyinstallanewblade.

Figure90

1.Cuttingedge3.Wear/slotforming

2.Curvedarea4.Crack

CheckingforBentBlades

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure91).Measurefromalevelsurfaceto thecuttingedge,positionA,oftheblades(Figure91). Notethisdimension.

Figure91

1.Measureherefromblade tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).Ifthis dimensionexceeds1/8inch(3mm),thebladeisbent andmustbereplaced;refertoRemovingtheBlades andInstallingtheBlades.

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedblade withanewblade.

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthebladeis outofbalanceorisbent.Toensureoptimumperformance andcontinuedsafetyconformanceofthemachine,use genuineTororeplacementblades.Replacementbladesmade

byothermanufacturersmayresultinnon-conformancewith safetystandards.

1.Holdthebladeendusingaragorthickly-paddedglove.

2.Removethebladebolt,curvedwasher,andbladefrom thespindleshaft(Figure92).

Figure92

1.Sailareaofblade3.Curvedwasher

2.Blade4.Bladebolt

SharpeningtheBlades

WARNING

Whensharpeningblades,piecesofabladecouldbe thrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpening blades.

1.Usealetosharpenthecuttingedgeatbothendsof theblade(Figure93).Maintaintheoriginalangle.The bladeretainsitsbalanceifthesameamountofmaterial isremovedfrombothcuttingedges.

Figure93

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitonablade balancer(Figure94).Ifthebladestaysinahorizontal position,thebladeisbalancedandcanbeused.Ifthe

bladeisnotbalanced,lesomemetalofftheendof thesailareaonly(Figure95).Repeatthisprocedure untilthebladeisbalanced.

Figure94

1.Blade2.Balancer

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure95).

Important:Thecurvedpartoftheblademustbe pointingupwardtowardtheinsideofthemowerto ensurepropercutting.

2.Installthespringdiskandthebladebolt.Thespring diskconemustbeinstalledtowardthebolthead (Figure95).Torquethebladeboltto115to150N-m (85to110ft-lb).

Figure95

1.Sailareaofblade

4.Bladebolt

2.Blade

5.Conetowardsbolthead

3.Curvedwasher

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,the spring-loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.

Donotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.

1.Stoptheengine,waitforallmovingpartstostop,and removethekey .Engagetheparkingbrake.

2.Removetheheight-adjustmentpinandlowerthedeck totheground.

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

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothesquare holeinthedeckidler(

Figure96).

6.Rotatethedeckidlerclockwiseandremovethemower belt(Figure96).

Figure96

1.Clutchpulley5.Squareholeintheidler armfortheratchet

2.Mowerbelt

6.Idlergreasetting

3.Spring-loadedidlerpulley

7.Beltguide

4.Ratchet

7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure97.

Figure97

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

8.Raisethedeckstrutsandsecurethemintheup position.Slidethedeckouttotherightsideofthe machine.

ReplacingtheGrassDeector

WARNING

Operatingthemachinewiththeenginerunningat aspeedgreaterthanthefactorysettingcancause themachinetothrowapartofthebladeorengine towardtheoperatororabystanderandresultin seriouspersonalinjuryordeath.

Neveroperatethemachineunlessyouinstallacover plate,amulchplate,agrassdeector,orabagger.

1.Removethelocknut,bolt,spring,andspacerholding thedeectortothepivotbrackets(Figure98).Remove thedamagedorworngrassdeector.

g015594

6 2

Figure98

1.Bolt

5.Springinstalled

2.Spacer6.Grassdeector

3.Locknut

7.Jhookendofspring

4.Spring

2.Placethespacerandthespringontothegrassdeector. PlaceoneJendofthespringbehindthedeckedge.

Note:MakesureoneJendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure98.

3.Installtheboltandthenut.PlaceoneJhookendof thespringaroundthegrassdeector(

Figure98).

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

Cleaning

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforallmoving partstostopbeforeleavingtheoperatingposition.

3.Raisethemowertothetransportposition.

WasteDisposal

Engineoil,batteries,hydraulicoil,andenginecoolantare pollutantstotheenvironment.Disposeoftheseaccordingto yourstateandlocalregulations.

Storage

CleaningandStorage

1.Disengagethepowertakeoff(blade-controlswitch (PTO),settheparkingbrake,andturntheignitionkey totheoffposition.Removethekey .

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engineandhydraulicsystem.Cleandirtandchafffrom theoutsideoftheenginecylinderheadnsandblower housing.

Important:Y oucanwashthemachinewithmild detergentandwater.Donotpressurewashthe machine.Avoidexcessiveuseofwater,especially nearthecontrolpanel,engine,hydraulicpumps, andmotors.

3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.

4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.

5.Greasethemachine;refertoGreasingandLubrication intheMaintenanceSection.

6.Changethecrankcaseoil;refertoServicingtheEngine OilintheMaintenanceSection.

7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.

8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.

9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.

10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:Runthemachinewiththeblade-controlswitch (PTO)engagedandtheengineathighidlefor2to 5minutesafterwashing.

11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.

12.Forstorageover30days,preparethemachineas follows:

A.Addapetroleum-basedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcohol-basedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandusedat alltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystem(5minutes).

C.Stoptheengine,allowittocool,anddrainthe

fueltank;refertoServicingtheFuelTankinthe MaintenanceSection.

D.Restarttheengineandrunituntilitstops.

E.Disposeoffuelproperly .Recycleasperlocal

codes.

Important:Donotstore stabilizer/conditionedfuelover90days.

13.Checkandtightenallbolts,nuts,andscrews.Repairor replaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

15.Storethemachineinaclean,drygarageorstoragearea. Removethekeyfromtheignitionswitchandkeepit outofreachofchildrenorotherunauthorizedusers. Coverthemachinetoprotectitandkeepitclean.

Troubleshooting

Problem

PossibleCauseCorrectiveAction

1.Theblade-controlswitch(PTO)is engaged.

1.Movetheblade-controlswitch(PTO)to thedisengagedposition.

2.Theparkingbrakeisnoton.

2.Settheparkingbrake.

3.Themotion-controlleversarenotinthe neutral-lockposition.

3.Ensurethatthemotion-controllevers areintheneutral-lockposition.

4.Theoperatorisnotseated.

4.Sitontheseat.

5.Thebatteryisdead.

5.Chargethebattery .

6.Theelectricalconnectionsarecorroded orloose.

6.Checktheelectricalconnectionsfor goodcontact.

7.Thefuseisblown.7.Replacethefuse.

Thestarterdoesnotcrank.

8.Therelayorswitchiswornordamaged.

8.ContactanAuthorizedServiceDealer.

1.Thefueltankisempty.1.Fillthefueltank.

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

3.Theoillevelinthecrankcaseislow .3.Addoiltothecrankcase.

4.Thethrottleisnotinthecorrectposition.4.Besurethatthethrottlecontrolis midwaybetweentheslowandfast positions.

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

6.Thereisdirt,water,orstalefuelisin

thefuelsystem.

6.ContactanAuthorizedServiceDealer.

7.Theaircleanerisdirty.

7.Cleanorreplacetheair-cleaner element.

8.Theseatswitchisnotfunctioning properly.

8.Checktheseat-switchindicator. Replacetheseatifnecessary.

9.Theelectricalconnectionsare corroded,loose,ordamaged.

9.Checktheelectricalconnections forgoodcontact.Cleanthe connectorterminalsthoroughly withelectrical-contactcleaner,apply dielectricgrease,andmakethe appropriateconnections.

10.Therelayorswitchiswornordamaged.

10.ContactanAuthorizedServiceDealer.

11.Thesparkplugisfouledorimproperly gapped.

11.Adjustorreplacethesparkplug.

Theenginedoesnotstart,startshard,or failstokeeprunning.

12.Thespark-plugwireisnotconnected.

12.Checkthespark-plugwireconnection.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty.

2.Cleantheair-cleanerelement.

3.Theoillevelinthecrankcaseislow .3.Addoiltothecrankcase.

4.Thecoolingnsandtheairpassages abovetheengineareplugged.

4.Removetheobstructionfromthe coolingnsandtheairpassages.

5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

Theenginelosespower.

7.Thereisdirt,water,orstalefuelisin thefuelsystem.

7.ContactanAuthorizedServiceDealer.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow .2.Addoiltothecrankcase.

Theengineoverheats.

3.Thecoolingnsandtheairpassages abovetheengineareplugged.

3.Removetheobstructionfromthe coolingnsandtheairpassages.

1.Thetrackingneedsadjustment1.Adjustthetracking.

Themowerpullstotheleftorright(with leversfullyforward)

2.Thetirepressureinthedrivetiresis notcorrect.

2.Adjustthetirepressureinthedrive tires.

Problem

PossibleCauseCorrectiveAction

1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.

2.Thepumpbeltisworn,loose,or broken.

2.Changethebelt.

3.Thepumpbeltisoffapulley.3.Changethebelt.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

Themachinedoesnotdrive.

5.Thehydraulicoillevelislowortoohot.5.Addhydraulicoiltothereservoirsorlet

itcooldown.

1.Thecuttingblade(s)is/arebentor unbalanced.

1.Installnewcuttingblade(s).

2.Theblademountingboltisloose.2.Tightentheblademountingbolt.

3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Theenginepulley,idlerpulley,orblade pulleyisloose.

4.Tightentheappropriatepulley .

5.Theenginepulleyisdamaged.

5.ContactanAuthorizedServiceDealer.

6.Thebladespindleisbent.

6.ContactanAuthorizedServiceDealer.

Themachinevibratesabnormally.

7.Themotormountislooseorworn.

7.ContactanAuthorizedServiceDealer.

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

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

3.Themowerdeckisnotlevel.

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

4.Theundersideofmowerisdirty .4.Cleantheundersideofthemower.

5.Thetirepressureisnotcorrect.5.Adjustthetirepressure.

Themachineproducesanunevencutting height.

6.Thebladespindleisbent.

6.ContactanAuthorizedServiceDealer.

1.Themowerdeckbeltisworn,loose, orbroken.

1.Installanewdeckbelt.

2.Themowerdeckbeltisoffpulley.

2.Installthemowerdeckpulleyand checktheidlerpulley ,idlerarm,and springforcorrectpositionandfunction.

3.Thepumpdrivebeltisworn,loose,or broken.

3.Checkthebelttensionorinstallanew belt.

Thebladesdonotrotate.

4.Theidlerspringisbrokenormissing.4.Replacethespring.

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

2.Thereislowvoltagesupplyatthe

clutch.

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

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchleadwireor electricalsystem.Cleantheconnector contacts.

Theclutchdoesnotengage.

5.Therotor/armatureairgapistoolarge.

5.Removetheshimorreplacetheclutch.

Schematics

WireDiagram(Rev.A)

Notes:

TheToroTotalCoverageWarranty

Landscape

ALimitedWarranty(seewarrantyperiodsbelow)Contractor

Equipment(LCE)

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuanttoan agreementbetweenthem,jointlypromisetotheoriginalpurchasertorepairtheToro Productslistedbelowifdefectiveinmaterialsorworkmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginalowner:

ProductsWarrantyPeriod

21in.Mowers2yearsResidentialUse

1yearCommercialUse

•Engines

Honda–2years

Kawasaki–3years

30in.Mowers2yearsResidentialUse

1yearCommercialUse

•Engines

Kawasaki–3years

Mid-SizeWalk-BehindMowers

2years

•Engines

Kawasaki–3years

GrandStand

Mowers

5yearsor1,200hours

•Engines

3years

•Frame

Lifetime(originalowneronly)

ZMaster

2000SeriesMowers

4yearsor500hours

•Engines

3years

•Frame

Lifetime(originalowneronly)

ZMaster

3000SeriesMowers

5yearsor1,200hours

•Engines

3years

•Frame

Lifetime(originalowneronly)

ZMaster

5000SeriesMowers

5yearsor1,200hours

•Engines

KohlerCommand–2years

KohlerEFI–3years

•Frame

Lifetime(originalowneronly)

ZMaster

6000SeriesMowers

5yearsor1,200hours

•Engines

Kawasaki–3years

•Frame

Lifetime(originalowneronly)

ZMaster

7000SeriesMowers

5yearsor1,200hours

•Engines

2years

•Frame

Lifetime(originalowneronly)

AllMowers

•Battery90daysPartsandLabor

1yearPartsonly

•BeltsandTires90days

•Attachments1year

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin normaluse,itwillberepairedorreplaced,atToro'soption,underwarrantyatnocostforparts andlabor .Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor corrosionarenotcovered.

SomeenginesusedonToroProductsarewarrantedbytheenginemanufacturer.

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsorworkmanship, followthisprocedure:

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

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

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’sanalysisorwith theassistanceprovided,contactusat:

RLCCustomerCareDepartment

ToroWarrantyCompany

811 1LyndaleAvenueSouth

Bloomington,MN55420-1196

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

888-865-5691(Canadacustomers)

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenanceprocedures describedintheOperator'sManual.Suchroutinemaintenance,whetherperformed byadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemissionsystemcoverage andenginewarrantycoverageonsomeproducts.Thisexpresswarrantydoesnot coverthefollowing:

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

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

•Componentsfailingduetonormalwear

•Anyproductorpartwhichhasbeenalteredormisusedorneglectedand

requiresreplacementorrepairduetoaccidentsorlackofpropermaintenance

•Pickupanddeliverycharges

•RepairsorattemptedrepairsbyanyoneotherthananAuthorizedT oroService

Dealer

•Repairsnecessaryduetofailuretofollowrecommendedfuelprocedure

(consultOperator'sManualformoredetails)

–Removingcontaminantsfromthefuelsystemisnotcovered

–Useofoldfuel(morethanonemonthold)orfuelwhichcontainsmore

than10%ethanolormorethat15%MTBE

–Failuretodrainthefuelsystempriortoanyperiodofnon-useoverone

month

GeneralConditions

AllrepairscoveredbythesewarrantiesmustbeperformedbyanAuthorizedT oro ServiceDealerusingT oroapprovedreplacementparts.

NeitherTheToroCompanynorT oroWarrantyCompanyisliableforindirect, incidentalorconsequentialdamagesinconnectionwiththeuseoftheT oro Productscoveredbythiswarranty ,includinganycostorexpenseofproviding substituteequipmentorserviceduringreasonableperiodsofmalfunctionor non-usependingcompletionofrepairsunderthiswarranty.

Allimpliedwarrantiesofmerchantability(thattheproductistforordinary use)andtnessforuse(thattheproductistforaparticularpurpose)are limitedtothedurationoftheexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequentialdamages, orlimitationsonhowlonganimpliedwarrantylasts,sotheaboveexclusions andlimitationsmaynotapplytoyou.

Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveotherrights whichvaryfromstatetostate.

CountriesOtherthantheUnitedStatesorCanada

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

AustralianConsumerLaw:AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.

374-0252RevF

Toro Z Master 3000 SERIES Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual