Toro Z Master 74941CP, Z Master 74943CP, Z Master 74945CP Operator's Manual

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FormNo.3370-939RevA

ZMaster

RidingMower

with48in,52inor60inTURBOFORCE DischargeMower

ModelNo.74941CP—SerialNo.312000001andUp

ModelNo.74943CP—SerialNo.312000001andUp

ModelNo.74945CP—SerialNo.312000001andUp

Side

ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)

Thisrotary-blade,ridinglawnmowerisintendedtobe

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

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

ThissparkignitionsystemcomplieswithCanadian ICES-002

Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisavailableas anoption.Ifyourequireasparkarrestor,contactyour AuthorizedToroDealer.

Wheneveryouneedservice,genuineToroparts, oradditionalinformation,contactanAuthorized ServiceDealerorToroCustomerServiceandhave themodelandserialnumbersofyourproductready. Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.

GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.

Note:ItisaviolationofCaliforniaPublicResource CodeSection4442touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.

Theenclosed

Engine Owner's Man ual

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

Introduction

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Y ouareresponsibleforoperating theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndingadealer, ortoregisteryourproduct.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjury ordeathifyoudonotfollowtherecommended precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Contactusatwww.Toro.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.......................................17

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

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

UsingtheFuelShut-OffValve............................18

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

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

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

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

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

AdjustingtheAnti-ScalpRollers.........................23

PositioningtheFlowBafe.................................24

PositioningtheSeat............................................24

UsingtheDriveWheelReleaseValves.................25

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

LoadingMachines..............................................26

TransportingMachines.......................................27

UsingtheZStand®............................................28

OperatingTips...................................................29

Maintenance...............................................................30

RecommendedMaintenanceSchedule(s)................30

Lubrication.............................................................31

GreasingandLubrication...................................31

WheretoGreasetheMower...............................31

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

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

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

ServicingtheSparkPlug.....................................36

CheckSparkArrester(ifequipped)......................37

FuelSystemMaintenance.......................................38

ReplacingtheFuelFilter.....................................38

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

ElectricalSystemMaintenance................................39

ServicingtheBattery...........................................39

ServicingtheFuses.............................................41

DriveSystemMaintenance.....................................41

CheckingtheSeatBelt........................................41

CheckingtheRolloverProtectionSystem

(ROPS)Knobs...............................................41

AdjustingtheTracking........................................42

CheckingtheTirePressure.................................42

CheckingtheWheelHubSlottedNut..................43

AdjustingtheCasterPivotBearing......................43

UsingtheClutchShim........................................43

CoolingSystemMaintenance..................................45

CleaningtheEngineScreenandEngineOil

Cooler............................................................45

CleaningtheEngineCoolingFinsand

Shrouds..........................................................45

CheckandCleantheHydraulicUnit

Shrouds..........................................................46

BrakeMaintenance.................................................47

AdjustingtheParkingBrake................................47

BeltMaintenance....................................................48

InspectingtheBelts............................................48

ReplacingtheMowerBelt...................................48

ReplacingtheHydraulicPumpDrive

Belt................................................................49

ControlsSystemMaintenance.................................50

AdjustingtheControlHandlePosition................50

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

AdjustingtheMotionControlDamper...............51

AdjustingtheMotionControlNeutralLock

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

HydraulicSystemMaintenance...............................52

ServicingtheHydraulicSystem...........................52

MowerDeckMaintenance......................................54

LevelingtheMowerDeck...................................54

ServicingtheCuttingBlades...............................57

RemovingtheMowerDeck................................59

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

Cleaning.................................................................61

CleaningUndertheMower.................................61

WasteDisposal...................................................61

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

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

Troubleshooting.........................................................63

Schematics.................................................................65

Safety

•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.

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

Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.

Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatchingcut grass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.

SafeOperatingPractices

ThefollowinginstructionsarefromANSIstandard B71.4-2004.

Training

–Useonlyanapprovedcontainer

–Neverrefuelordrainthemachineindoors.

–Neverremovegascaporaddfuelwithengine

running.Allowenginetocoolbeforerefueling. Donotsmoke.

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

Operation

•Neverrunanengineinanenclosedarea.

•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.

•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator'sposition.Useseatbeltswiththe rollbarinthefullyraisedandlockedposition.

•Neverraisemowerwiththebladesrunning.

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

•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.

•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.

Preparation

•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.

•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.

•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.

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

•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.

•Donotchangetheenginegovernorsettingor overspeedtheengine.

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

•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.

•Keephandsandfeetawayfromthecuttingunits.

•Nevercarrypassengersandkeeppetsandbystanders away.

•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.

•Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.

•Beawareofthemowerdischargedirectionanddo notpointitatanyone.

•Donotoperatethemowerundertheinuenceof alcoholordrugs.

•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.

SlopeOperation

•Donotmowslopesgreaterthan15degrees.

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

•Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.

•Donotmakesuddenturnsorrapidspeedchanges.

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

•Reducespeedanduseextremecautiononslopes.

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

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

•Avoidsuddenstartswhenmowinguphillbecausethe mowermaytipbackwards.

•Beawarethatoperatingonwetgrass,acrosssteep slopes,ordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.

•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.

•Followthemanufacturer'srecommendationsfor wheelweightsorcounterweightstoimprovestability.

•Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.

UsingtheRolloverProtectionSystem (ROPS)

•Keeptherollbarinthefullyraisedandlocked positionandusetheseatbeltwhenoperatingthe machine.

•Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.

•Beawarethereisnorolloverprotectionwhenthe rollbarisdown.

•Checktheareatobemowedandneverfoldthe ROPSinareaswherethereareslopes,dropoffsor water.

•Lowertherollbaronlywhenabsolutelynecessary. Donotweartheseatbeltwiththerollbarfolded down.

•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforedriving underanyobjectsanddonotcontactthem.

Maintenanceandstorage

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

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

•Letenginecoolbeforestoringanddonotstorenear ame.

•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.

•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.

•Usejackstandstosupportcomponentswhen required.

•Carefullyreleasepressurefromcomponentswith storedenergy.

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

•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplacedamagedblades;neverstraightenor weldthem.

•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.

•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.Wear protectiveclothinganduseinsulatedtools.

•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.

•UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.

SlopeIndicator

G011841

Figure3

Thispagemaybecopiedforpersonaluse.

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

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

3.Exampleofhowtocompareslopewithfoldededge.

SafetyandInstructional Decals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.

68-8340

1-403005

98-5954

103–2076

54-9220

58-6520

1.Grease

105-7798

66-1340

110-2067

110-2068

107-3069

1.Warning–thereisnorolloverprotectionwhentherollbaris down.

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

3.ReadtheOperator'sManual;driveslowlyandcarefully.

109-7232

1.Fast3.Neutral

2.Slow

4.Reverse

1.ReadtheOperator'sManual.

114-4466

1.Main,25A

2.PTO,10A

3.Charge,25A

4.Auxiliary,15A

116-1716

1.Fuel6.Hourmeter

2.Empty

3.Half

4.Full9.Neutral

5.Battery

7.PTO

8.Parkingbrake

10.Operatorpresenceswitch

1.Greasepulleys

2.Maintenanceinterval—50

116-0211

115-7445

116-0157

116-0752

1.Locked2.Unlocked

116-2643

116-0205

116-3303

BatterySymbols

Someorallofthesesymbolsareonyourbattery

116-5944

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe

7.Weareyeprotection;

8.Batteryacidcancause

10.Containslead;donot

distancefromthebattery .

explosivegasescan causeblindnessandother injuries

blindnessorsevereburns.

withwaterandgetmedical helpfast.

discard.

116-1654

117-0346

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

Manufacturer'sMark

1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.

116-4858

120-5897

1.Choke4.Slow

2.Fast

3.Continuousvariable setting

5.Powertake-off(PTO), Bladecontrolswitch

120-5898

1.Choke4.Slow

2.Fast

3.Continuousvariable setting

5.Powertake-off(PTO), Bladecontrolswitch

109-7069

ProductOverview

G008951

Figure4

1.Height-of-cutdecklift pedal

2.Transportlock8.Fuelcap

3.Parkingbrakelever9.Mowerdeck

4.Controls10.Casterwheel

5.Motioncontrollevers

6.Rollbar

7.Seatbelt

11.ZStand®

HourMeter

Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance (Figure6).

FuelGauge

Thefuelgaugeislocatedwiththehourmeterandthe barslightupwhentheignitionswitchison(Figure6).

Theindicatorlightappearswhenthefuellevelislow (approximatelyonegallonremaininginthefueltank).

SafetyInterlockIndicators

Therearesymbolsonthehourmeterandtheindicate withablacktrianglethattheinterlockcomponentisin thecorrectposition(Figure6).

BatteryIndicatorLight

IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure6).

Controls

Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure4andFigure5).

Figure5

1.PTOSwitch4.Hourmeter/Safety

2.Choke

3.Throttlecontrol6.Fuses

5.Ignitionswitch

interlockdisplay/Fuel gauge

Figure6

1.Fuelgauge(bars)4.Safetyinterlocksymbols

2.Batterylight

3.Hourmeter

5.Lowfuelindicatorlight

ThrottleControl

ThethrottlecontrolisvariablebetweenFastandSlow.

Choke

Usethechoketostartacoldengine.Pullthechoke knobuptoengageit.

BladeControlSwitch(PTO)

Specications

Thebladecontrolswitch(PTO)isusedtoengagethe electricclutchanddrivethemowerblades.Pullthe switchuptoengagethebladesandrelease.Todisengage theblades,pushthebladecontrolswitch(PTO)down ormoveamotioncontrolleverintotheneutrallock position.

IgnitionSwitch

Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.

MotionControlLevers

Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.

NeutralLockPosition

Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.

FuelShut-offValve

Closethefuelshut-offvalve(undertheseat)when transportingorstoringthemower.

Note:Specicationsanddesignaresubjecttochange withoutnotice.

Width:

48inchDeck52inchDeck

WithoutDeck

DeectorUp54inches(137.2

DeectorDown63.6inches(161.4

WithoutDeck

DeectorUp61.7inches(156.8

DeectorDown75.7inches(192.2

45.7inches(116.1 cm)

cm)

60inchDeck

53.0inches(134.6 cm)

cm)

45.7inches(116.1 cm)

57.5inches(146.0 cm)

67.6inches(171.8 cm)

Length:

48inchDeck52inchDeck

RollBar-Up

RollBar-Down

79.2inches(201.2 cm)

80.9inches(205.5 cm)

79.2inches(201.2 cm)

80.9inches(205.5 cm)

Attachments/Accessories

AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.

60inchDeck

RollBar-Up

RollBar-Down

83.1inches(211.1 cm)

84.8inches(215.4 cm)

Height:

RollBar-UpRollBar-Down

70.5inches(179.1cm)46.8inches(1 18.9cm)

Weight:

ModelWeight

74941CP1147lb(520kg)

74943CP1147lb(520kg)

74945CP1255lb(569kg)

Operation

Note:Determinetheleftandrightsidesofthe

machinefromthenormaloperatingposition.

AddingFuel

•Forbestresults,useonlyclean,fresh,unleaded gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).

•Oxygenatedfuelwithupto10%ethanolor15% MTBEbyvolumeisacceptable.

•DoNotuseethanolblendsofgasoline(suchasE15 orE85)withmorethan10%ethanolbyvolume. Performanceproblemsand/orenginedamagemay resultwhichmaynotbecoveredunderwarranty.

•DoNotusegasolinecontainingmethanol.

•DoNotstorefueleitherinthefueltankorfuel containersoverthewinterunlessafuelstabilizeris used.

•DoNotaddoiltogasoline.

DANGER

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

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.

DANGER

Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.

•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

WARNING

Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.

•Avoidprolongedbreathingofvapors.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.

•Keepfaceawayfromnozzleandgastankor conditioneropening.

•Keepgasawayfromeyesandskin.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:

•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.

•Cleanstheenginewhileitruns

•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting

Important:Donotusefueladditivescontaining methanolorethanol.

Addthecorrectamountofgasstabilizer/conditioner tothegas.

Note:Afuelstabilizer/conditionerismosteffective

G008942

whenmixedwithfreshgasoline.T ominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.

FillingtheFuelTank

Note:Donotllthefueltankcompletelyfull,thiswill

allowgasolinetoexpand.Allowa1/4to1/2inch(6 mmto13mm)spacebelowthebreathervalvelocated onthellerneck.

1.Shuttheengineoffandsettheparkingbrake.

2.Cleanaroundthefueltankcap.

3.Fillthefueltank.Ensurethereisspacebelowthe breathervalveasshownin

Figure7.

BreakingInaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew , placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.

UsingtheRolloverProtection System(ROPS)

WARNING

Toavoidinjuryordeathfromrollover:keepthe rollbarinthefullyraisedlockedpositionanduse theseatbelt.

Ensuretheseatissecuredtothemachine.

WARNING

Thereisnorolloverprotectionwhentherollbar isinthedownposition.

Figure7

•Lowertherollbaronlywhenabsolutely necessary.

•Donotweartheseatbeltwhentherollbaris inthedownposition.

•Driveslowlyandcarefully.

•Raisetherollbarassoonasclearancepermits.

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

Important:Lowertherollbaronlywhen absolutelynecessary.

Important:Ensuretheseatissecuredtothe machine.

1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.

2.Pullbothknobsoutandrotatethem90°sotheyare notengaged(Figure8).

3.Lowertherollbartothedownposition(Figure8).

CheckingtheEngineOilLevel

Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking theEngineOilLevel.

DANGER

Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.

Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.

Thereisnorolloverprotectionwhentherollbar isdown.

Alwayskeeptherollbarinthefullyraisedand lockedpositionandusetheseatbelt.

Readandfollowtherolloverprotectioninstructions andwarnings.

Toavoidlossofcontrolandpossibilityofrollover:

•Donotoperateneardrop-offsornearwater.

•Donotoperateonslopesgreaterthan 15degrees.

•Reducespeedanduseextremecautionon slopes.

Figure8

1.ROPSknob

2.PullROPSknoboutand rotate90degrees

3.Rollbarintheupright position

4.Rollbarinthefolded position

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

5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins

Figure8).Pushontherollbarandensurethat

( bothpinsareengaged.

Important:Alwaysusetheseatbeltwiththe rollbarinthefullyraisedposition.

•Avoidsuddenturnsorrapidspeedchanges.

Figure9

1.SafeZone-usethe ZMasterhereonslopes lessthan15degreesor atareas.

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

3.Water

ThinkSafetyFirst

Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.

CAUTION

G009027

G016994

G016995

G008945

G009174

Thismachineproducessoundlevelsinexcessof 85dBAattheoperatorsearandcancausehearing lossthroughextendedperiodsofexposure.

Wearhearingprotectionwhenoperatingthis machine.

Theuseofprotectiveequipmentforeyes,ears,feetand headisrecommended.

ReleasingtheParkingBrake

Figure12

OperatingtheMowerBlade ControlSwitch(PTO)

Figure10

1.Wearsafetyglasses

2.Wearhearingprotection

OperatingtheParkingBrake

Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.

SettingtheParkingBrake

WARNING

Parkingbrakemaynotholdmachineparkedona slopeandcouldcausepersonalinjuryorproperty damage.

Donotparkonslopesunlesswheelsarechocked orblocked

Thebladecontrolswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

EngagingtheBladeControlSwitch (PTO)

Note:Engagingthebladecontrolswitch(PTO)with

thethrottlepositionathalforlesswillcauseexcessive weartothedrivebelts.

Figure13

DisengagingtheBladeControlSwitch (PTO)

Figure11

Figure14

OperatingtheThrottle

ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure15).

Alwaysusethefastpositionwhenturningonthe

G008946

G008959

START

RUN

STOP

G008947

G008948

mowerdeckwiththebladecontrolswitch(PTO).

Figure15

OperatingtheChoke

tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely .

Usethechoketostartacoldengine.

1.Iftheengineiscold,usethechoketostartthe engine.

2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(Figure16).

3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure16).

Figure17

2.Turntheignitionkeytostoptostoptheengine.

UsingtheFuelShut-OffValve

Thefuelshut-offvalveislocatedundertheseat.Move theseatforwardtoaccessit.

Closethefuelshut-offvalvefortransport,maintenance, andstorage.

Ensurethefuelshut-offvalveisopenwhenstarting theengine.

Figure16

1.On2.Off

Figure18

1.On2.Off

OperatingtheIgnitionSwitch

1.TurntheignitionkeytotheStartposition (Figure17).Whentheenginesstarts,releasethekey.

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails

StartingandStoppingthe

g017006

START

RUN

STOP

G008947

Engine

StartingtheEngine

1.RaisetheROPSupandlockintoplace,sitonthe seatandfastentheseatbelt.

2.Movethemotioncontrolstoneutrallocked position.

3.Settheparkingbrake;refertoSettingtheParking Brake.

4.Movethebladecontrolswitch(PTO)totheOff position(

5.MovethethrottlelevermidwaybetweentheSlow andFastpositions.

Figure19).

Figure20

1.Off3.Start

2.Run

StoppingtheEngine

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Figure19

6.TurntheignitionkeytotheStartposition (Figure17).Whentheenginesstarts,releasethekey.

Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.

Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely .

g017007

TheSafetyInterlockSystem

G009181

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

UnderstandingtheSafetyInterlock System

Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:

•Youaresittingontheseat.

•Theparkingbrakeisengaged.

•Thebladecontrolswitch(PTO)isdisengaged.

•Themotioncontrolleversareintheneutrallocked position

Figure21

Important:Makesurethatthefuelshutoffvalveis

closedbeforetransportingorstoringthemachine, asfuelleakagemayoccur.Settheparkingbrake beforetransporting.Makesuretoremovethekey asthefuelpumpmayrunandcausethebattery tolosecharge.

Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOisengaged.

Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.

Figure22

1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition

TestingtheSafetyInterlockSystem

ServiceInterval:Beforeeachuseordaily

Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot

operateasdescribedbelow ,haveanAuthorizedService Dealerrepairthesafetysystemimmediately.

1.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)toon.Try startingtheengine;theengineshouldnotcrank.

2.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)tooff.Move eithermotioncontrollever(outofneutrallocked position).Trystartingtheengine;theengineshould notcrank.Repeatforothercontrollever.

3.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, releasetheparkingbrake,engagethebladecontrol switch(PTO)andriseslightlyfromtheseat;the engineshouldstop.

4.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, centereithermotioncontrolandmove(forwardor reverse);theengineshouldstop.Repeatforother motioncontrol.

5.Sittingontheseat,disengagetheparkingbrake, movethebladecontrolswitch(PTO)tooffand movethemotioncontrolleverstoneutrallock position.Trystartingtheengine;theengineshould notcrank.

UsingtheMotionControlLevers

Figure23

1.Motioncontrol lever-neutrallockposition

2.Center,unlockedposition5.Frontofmachine

3.Forward

4.Backward

DrivingForwardorBackward

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

CAUTION

Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.

•Usecautionwhenmakingturns.

•Slowthemachinedownbeforemakingsharp turns.

DrivingForward

Note:Theenginewillkillifthetractioncontrollevers

aremovedwiththeparkingbrakeengaged.

Tostop,pullthemotioncontrolleverstotheneutral position.

1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.

2.Movetheleverstothecenter,unlockedposition.

3.Togoforward,slowlypushthemotioncontrol leversforward(

Figure24).

G008952

G008953

StoppingtheMachine

Tostopthemachine,movethetractioncontrollevers toneutralandmovetolockedposition,disengagethe powertakeoff(bladecontrolswitch(PTO),andturn theignitionkeytooff.

Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.

Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.

Figure24

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.

2.Togobackward,slowlypullthemotioncontrol leversrearward(Figure25).

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhastwopositionsandisusedwith thedeckliftpedal.Thereisalockpositionandaunlock positionforthetransportposition.Thetransportlock isusedwiththedeckliftpedal.Referto

Figure26

Figure25

AdjustingtheHeight-of-CutPin

G017027

Theheight-of-cutisadjustedfrom1to5-1/2inches (25to140mm)in1/4inch(6mm)incrementsby relocatingtheclevispinintodifferentholelocations.

1.Movethetransportlocktothelockposition.

2.Pushonthedeckliftpedalwithyourfootandraise themowerdecktothetransportposition(also the5-1/2inch(140mm)cuttingheightposition)

Figure27).

(

3.Toadjust,rotatethepin90degreesandremovethe pinfromtheheight-of-cutbracket(

4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(Figure27).

5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.

Figure27).

Figure26

TransportLockPositions

1.Transportlock3.Unlockposition—doesnot lockthemowerdeckinto transportposition

2.Lockposition—mower

deckwilllockintotransport position

Figure27

1.Deckliftpedal

2.Cutofheightpin

3.Transportlock

AdjustingtheAnti-Scalp Rollers

Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.

1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.

2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.

Figure28

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

Figure30

1.Anti-scalproller4.FlangeNut

2.Spacer

3.Bushing

5.Bolt

PositioningtheFlowBafe

Theowbafeisadjustablebylooseningthenutson topofthemowerdeck.Adjustmentswillvarybygrass type,moisturecontent,andheightofgrass.Always alignthebafewiththebloweropeningwhenabagger isinstalled.

Figure29

1.Anti-scalproller3.FlangeNut

2.Bushing4.Bolt

Figure31

1.Nutsforpositioningtheowbafe

PositioningtheSeat

ChangingtheSeatPosition

Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.

1.Toadjust,movetheleversidewaystounlockseat (Figure32).

2.Slidetheseattothedesiredpositionandrelease levertolockinposition.

ChangingtheSeatSuspension

Theseatcanbeadjustedtoprovideasmoothand comfortableride.Positiontheseatwhereyouaremost comfortable.

Toadjustit,turntheknobinfronteitherdirectionto providethebestcomfort(

Figure32).

AdjustingtheArmrestPosition

Thearmrestscanbeadjustedtoprovideasmoothand comfortableride.Positionthearmrestswhereyouare mostcomfortable.

Toadjustit,liftthearmrestsandturntheknobineither directiontoprovidethebestcomfort(

Figure32).

ChangingtheBackPosition

Thebackoftheseatcanbeadjustedtoprovidea comfortableride.Positionthebackoftheseatwhereit ismostcomfortable.

Toadjustit,turntheknob,undertheright-sidearm rest,ineitherdirectiontoprovidethebestcomfort (Figure32).

Figure32

1.Backrestknob3.Right-sidearmrest

2.Seatpositionadjustment lever

4.Armrestadjustmentknob

UsingtheDriveWheelRelease Valves

WARNING

Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury.

Stoptheengine,removethekey,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.

WARNING

Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulicdrive unitscancausesevereburns.

Allowtheengineandhydraulicdriveunitstocool completelybeforeaccessingthedrivewheelrelease valves.

Thedrivewheelreleasevalvesarelocatedinthebackof eachhydraulicdriveunit,undertheseat.

Note:Makesurethereleasevalvesareinthefully horizontalpositionwhenoperatingthemachineor severedamagetothehydraulicsystemcanoccur.

1.DisengagethePTO(bladecontrolswitch)andturn theignitionkeytooff.Movetheleverstoneutral lockedpositionandapplyparkingbrake.Remove thekey.

2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthe pumpenablingthewheelstoturn(

Figure33).

3.Disengageparkingbrakebeforepushing.

DANGER

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

•Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthemower.

•Nevertrytoclearthedischargeareaormower bladesunlessyoumovethepowertakeoff (bladecontrolswitch(PTO)totheoffposition, rotatetheignitionkeytooffandremovethekey .

•Makesurethegrassdeectorisinthedown position.

Figure33

1.Verticaltopushthe machine

2.Horizontaltorunthe machine

4.Rotatethereleasevalvelevershorizontallytorun themachine(Figure33).

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.

LoadingMachines

Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure34). Thelowerrearsectionofthetractorframeextendsback betweentherearwheelsandservesasastopfortipping backward.Havingafullwidthrampprovidesasurface fortheframememberstocontactiftheunitstartsto tipbackward.Ifitisnotpossibletouseonefullwidth ramp,useenoughindividualrampstosimulateafull widthcontinuousramp.

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

Figure34).Asteeperangle

Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.

Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.

WARNING

TransportingMachines

Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.

•Useextremecautionwhenoperatingauniton aramp.

•EnsuretheROPSisintheuppositionwhile usingtheseatbeltwhenloadingthemachine. EnsuretheROPSwillclearthetopofan enclosedtrailer.

•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.

•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.

•Donotexceeda15degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.

•Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.

Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby law .Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.

WARNING

Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow movingvehicleemblemisdangerousandcanlead toaccidentscausingpersonalinjury.

Donotdrivemachineonapublicstreetorroadway.

Totransportthemachine:

1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakes.

3.Loadthemachineontothetrailerortruck.

•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.

Figure34

1.Trailer3.Notgreaterthan 15degrees

2.Fullwidthramp4.Fullwidthramp—sideview

4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.

5.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(

Figure35

1.Tractionunittiedownloops

Figure35).

UsingtheZStand®

TheZStand®raisesthefrontendofthemachineto allowyoutocleanthemowerandremovetheblades.

WARNING

Themachinecouldfallontosomeoneandcause seriousinjuryordeath.

•Useextremecautionwhenoperatingthe machineontheZStand®.

•Useonlyforcleaningthemowerandremoving theblades.

1.ZStand(Positionedin slot)

2.Crackinsidewalkorturf

Figure37

3.Latchrestingonpivottab

•DonotkeepthemachineontheZStandfor extendedperiodsoftime.

•Alwaysturntheengineoff,settheparking brake,andremovethekeybeforeperforming anymaintenancetothemower.

DrivingupontotheZStand

Important:UsetheZStandonalevelsurface.

1.Raisethemowertothetransportposition.

2.Removethebracketpin(Figure36).

4.Setthefootofstandonthegroundandrestthe latchonthepivottab(Figure37).

5.Starttheengineandputitathalfthrottle.

Note:Forbestresults,placethefootofstandinto seamsinsidewalksorintotheturf(

Figure37).

6.Driveontothestand.Stopwhenthelatchdrops overthetabintothelockedposition(Figure37). Onceontothestand,engagetheparkingbrakeand tunofftheengine.

7.Chockorblockthedrivewheels.

WARNING

Parkingbrakemaynotholdmachineparked onZStandandcouldcausepersonalinjuryor propertydamage.

DonotparkonZStandunlesswheelsare chockedorblocked.

8.Performthemaintenance.

Figure36

1.ZStand4.Bottomofslot

2.BracketPin5.Latch

3.Bracket

3.Raisethelatch.Swingthestandfootoutfrontand slidestandtowardmachine,intothebottomofslot (

Figure36andFigure37).

DrivingofftheZStand

1.Removethechocksorblocks.

2.Raisethelatchtotheunlockedposition(

Figure38).

MowatCorrectIntervals

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

Figure38

1.ZStand

2.Latch4.Unlockedposition

3.Starttheengineandplaceitathalfthrottle. Disengagetheparkingbrake.

4.Slowlydrivebackwardsoffofthestand.

5.Returnthestandtoitsrestposition(Figure36).

3.Lockedposition

OperatingTips

FastThrottleSetting

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

CuttingaLawnfortheFirstTime

CuttingSpeed

Toimprovecutquality ,useaslowergroundspeedin certainconditions.

AvoidCuttingTooLow

Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.

LongGrass

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

WhenStopping

Ifthemachine'sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyour lawn.Toavoidthis,moveontoapreviouslycutarea withthebladesengaged.

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

Cut1/3oftheGrassBlade

Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.

MowingDirection

Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.

KeeptheUndersideoftheMower Clean

Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.

BladeMaintenance

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

Maintenance

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst100hours

Beforeeachuseordaily

Every50hours

Every100hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Checktheparkbrakeadjustment.

•Checkthesafetysystem.

•Checktheengineoillevel.

•Checktheseatbelt.

•Checktherolloverprotectionsystem(ROPS)knobs.

•Cleantheenginescreenandtheoilcooler.

•Checkandcleanthehydraulicunitshrouds.

•Checkthemowerblades.

•Cleanthemowerdeck.

•Greasethemowerdeckspindlesandidlerarm.

•Checksparkarrester(ifequipped).

•Checkthetirepressure.

•Inspectthebeltsforcracksandwear.

•Checkthehydraulicoillevel.

•Lubricatethemowerdeckliftpivots.

•Changetheengineoil.(moreoftenindirtyordustyconditions)

•Check,cleanandregapthesparkplug.

•Checkandcleanenginecoolingnsandshrouds.

Every200hours

Every250hours

Every500hours

Monthly

Yearly

Yearlyorbeforestorage

•Changetheengineoillter.

•Replacetheprimaryairlter.

•Checkthesecondaryairlter.

•ChangethehydraulicltersandhydraulicoilwhenusingMobil1oil.

•Replacethesecondaryairlter.

•Replacethefuellter.(moreoftenindirtyordustyconditions).

•Checkthewheelhubslottednuttorque.

•Checkthetorqueforwheellugnuts.

•Adjustthecasterpivotbearing.

•Checktheparkbrakeadjustment.

•ChangethehydraulicltersandhydraulicoilwhenusingT oro®HYPR-OIL™500 hydraulicoil

•Checkthebattery .

•Greasethepumpbeltidlerarm.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).

•Paintchippedsurfaces.

•Checkallmaintenanceprocedureslistedabovebeforestorage.

Important:Refertoyourengineoperator'smanualforadditionalmaintenanceprocedures.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoanymaintenance.

Lubrication

G017028

G009029

GreasingandLubrication

Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy.

GreaseType:No.2generalpurposelithiumbaseor molybdenumbasegrease

WheretoGreasetheMower

ServiceInterval:Every50hours—Greasethemower

deckspindlesandidlerarm.

Yearly—Greasethepumpbeltidler arm.

Yearly—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).

HowtoGrease

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

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

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

5.Wipeupanyexcessgrease.

WheretoAddLightOilorSpray Lubrication

ServiceInterval:Every100hours

Lubricatethedeckliftpivots.

Yearly—Repackthefrontcaster wheelbearings(moreoftenindirtyor dustyconditions).

Important:Makesurecuttingunitspindlesarefull ofgreaseweekly.

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

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(

4.Greasethettingsonthetopofthe3spindle bearingsuntilgreasecomeoutthebottom

Figure40).

(

Figure40).

Figure39

Figure40

5.Greasethedrivebeltidlerarm(Figure40).

EngineMaintenance

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.

ServicingtheAirCleaner

ServiceInterval:Every250hours—Replacethe

primaryairlter.

Figure41

6.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.

7.Removethehexplug.Threadagreasezerkintothe hole.

8.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.

9.Removethegreasezerkinthehole.Installthehex pluganddustcap(

Figure42).

Every250hours—Checkthe secondaryairlter.

Every500hours—Replacethe secondaryairlter.

Note:Servicetheaircleanermorefrequentlyif operatingconditionsareextremelydustyorsandy .

RemovingtheFilters

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Pushdowntoreleasetheretainingclampsontheair cleanerandpulltheaircleanercoveroffoftheair cleanerbody(

4.Cleantheinsideoftheaircleanercoverwith compressedair.

Figure43).

Figure42

10.Greasethecasterwheelbearings(Figure42).

5.Gentlyslidetheprimarylteroutoftheaircleaner

Figure43).Avoidknockingthelterintothe

body( sideofthebody .

6.Removethesecondarylteronlyifyouintendto replaceit.

Important:Neverattempttocleanthe secondarylter.Ifthesecondarylterisdirty, thentheprimarylterisdamagedandyou shouldreplacebothlters.

7.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutside ofthelter.Holesinthelterwillappearasbright spots.Ifthelterisdamageddiscardit.

Figure43

ServicingtheEngineOil

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

OilCapacity:withalterchange,77ounces(2.3L);

withoutalterchange,70ounces(2.1L)

Viscosity:Seethetablebelow .

1.Aircleanerclamps

2.Aircleanercover

3.Primaryairlter

4.Secondaryairlter

ServicingthePrimaryFilter

1.Donotcleanthepaperlter,replaceit(Figure43).

2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.

3.Replacethepaperelementifitisdamaged.

ServicingtheSecondaryFilter

Donotcleanthesecondarylter,replaceit.

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

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandcover installed.

Figure44

Note:Useofmulti-gradeoils(5W -20,10W -30,or

10W-40)willincreaseoilconsumption.Checktheoil levelmorefrequentlywhenusingthem.

CheckingtheEngineOilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.

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

2.Ifthesecondarylterisbeingreplaced,carefully slideitintothelterbody(Figure43).

3.Carefullyslidetheprimarylteroverthesecondary lter(Figure43).Ensurethatitisfullyseatedby pushingontheouterrimofthelterwhileinstalling it.

Important:Donotpressonthesoftinsidearea ofthelter.

4.Installtheaircleanercoverwiththebreathercap downandrotatesotheretainingclampslockthe coverinplace(

Figure43).

Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure45).

G008804

G008792

ChangingtheEngineOil

G008804

G008793

ServiceInterval:Aftertherst8hours

Every100hours(moreoftenindirty ordustyconditions)

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothattherearisslightlylower thanthefronttoensuretheoildrainscompletely .

2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(

Figure46).

Figure45

Figure46

4.Slowlypourapproximately80%ofthespeciedoil

G008796

G008804

G008748

3/4

intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure47).

Figure47

5.Starttheengineanddrivetoaatarea.Checkthe oillevelagain.

ChangingtheEngineOilFilter

ServiceInterval:Every200hours

Note:Changetheengineoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.

1.Draintheoilfromtheengine;refertoChangingthe EngineOil.

2.Changetheengineoillter(

Figure48).

Figure48

Note:Ensuretheoilltergaskettouchestheengine

andthenanextra3/4turniscompleted.

3.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.

ServicingtheSparkPlug

G008803

ServiceInterval:Every100hours

Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.

Type:NGK

BPR4ESorequivalent

AirGap:0.030inch(0.75mm)

RemovingtheSparkPlug

1.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Removethelefthandhydraulicunitshroudinthe orderlistedwith tothefrontsparkplug.

Figure49.Thisgivesyouaccess

1.Pullthistabouttothe sideinthedirectionofthe arrow

2.Pulltheshroudoffofthis frametabinthedirection ofthearrow

Figure49

3.Pulltheshroudoffofthis frametabinthedirection ofthearrow

4.Shroud

4.Removethesparkplug.

Figure50

5.Installthelefthandhydraulicunitshroud(Figure49).

CheckingtheSparkPlug

G008794

G015200

CheckSparkArrester(if

Important:Nevercleanthesparkplug(s).Always

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

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.

Setthegapto0.030inches(0.76mm).

Figure51

InstallingtheSparkPlug

Tightenthesparkplug(s)to16ft.-lb(22N-m).

equipped)

ServiceInterval:Every50hours

WARNING

Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresultin personalinjuryorpropertydamage.

DoNotrefuelorrunengineunlesssparkarrester isinstalled.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Waitformufertocool.

3.Ifanybreaksinthescreenorweldsareobserved, replacethearrester.

4.Ifpluggingofthescreenisobserved,removethe arresterandshakelooseparticlesoutofthearrester andcleanscreenwithawirebrush(soakinsolventif necessary).Reinstallarresteronexhaustoutlet.

Figure52

FuelSystem

G008963

12

Maintenance

Note:Itisimportanttoreinstallthefuellinehosesand securewithplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineawayfrom componentsthatcouldcausefuellinedamage.

ReplacingtheFuelFilter

ServiceInterval:Every500hours/Yearly(whichever

comesrst)(moreoftenindirtyor dustyconditions).

Thefuellterislocatedneartheengineonthefront orrearsideoftheengine.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Allowthemachinetocooldown.

4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

5.Closethefuelshutoffvalveundertheseat (Figure53).

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.

Figure53

1.Fuellter

2.Hoseclamp

6.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(Figure53).

7.Removethelterfromthefuellines.

8.Installanewlterandmovethehoseclampsclose

9.Openthefuelshutoffvalve.

tothelter(

Figure53).

3.Fuelline

ElectricalSystem Maintenance

ServicingtheBattery

ServiceInterval:Monthly

WARNING

CALIFORNIA

Proposition65Warning

WARNING

Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.

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

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

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

W ash hands after handling .

DANGER

Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.

Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.

RemovingtheBattery

WARNING

Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Firstdisconnectthenegativebatterycable(black) fromthenegative(-)(black)batteryterminal

Figure54).

(

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

5.Removethewingnutsecuringthebatteryclamp (Figure54).

6.Removetheclamp(

7.Removethebattery.

Figure54).

•Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.

•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.

G008804

g014731

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

1.Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.

2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(

Figure55).

3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.

Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.

Figure54

1.Removethewingnutand clamp

2.Removethenegative batterycablebeforethe positive

3.Removethepositive batterycable

4.Removebattery

InstallingtheBattery

1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure54).

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

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

4.Securethecableswith2bolts,2washers,and 2locknuts(

5.Slidetheredterminalbootontothepositive(red) batterypost.

6.Installtheclampandsecureitwiththewingnut (Figure54).

Figure54).

1.PositiveBatteryPost

2.NegativeBatteryPost

Figure55

3.Red(+)ChargerLead

4.Black(-)ChargerLead

ChargingtheBattery

WARNING

Chargingthebatteryproducesgassesthatcan explode.

Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.

ServicingtheFuses

DriveSystem

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

1.Thefusesarelocatedonrighthandconsolenextto theseat(

2.Toreplacethefuses,pulloutonthefusetoremove it.

3.Installanewfuse(Figure56).

Figure56).

Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily

Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.

CheckingtheRollover ProtectionSystem(ROPS) Knobs

ServiceInterval:Beforeeachuseordaily

WARNING

Toavoidinjuryordeathfromrollover:keeptheroll barinthefullyraisedlockedpositionandusethe seatbelt.

Figure56

1.Optionalaccesory-15amp

2.Charge-25amp5.Console

3.PTO-10amp

Ensuretheseatissecuredtothemachine.

Checkthatboththemountinghardwareandtheknobs

4.Main-25amp

areingoodworkingcondition.Makesuretheknobs arefullyengagedwiththeROPSintheraisedposition. Theupperhoopoftherollbarmayneedtobepushed forwardorpulledrearwardtogetbothknobsfully engaged.

Figure58

Leftcontrollevershown

1.Controllever3.Stopplate

2.Bolt

Figure57

1.ROPSknob(locked position)

2.PullROPSknoboutand rotate90degreesto changerollbarposition

3.Rollbarintheupright position

4.Rollbarinthefolded position

AdjustingtheTracking

1.Disengagethebladecontrolswitch(PTO).

2.Drivetoanopenatarea,movethemotioncontrol leverstotheneutrallockedposition.

3.Movethethrottlemidwaybetweenfastandslow .

4.Movebothmotioncontrolleversallthewayforward untiltheybothhitthestopsintheT-slot.

5.Checkwhichwaythemachinetracks.

6.Ifittrackstotheright,loosentheboltsandadjust theleftstopplateontheleftT-slotuntilthemachine tracksstraight(

7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplateontherightT-slotuntilthemachine tracksstraight(Figure58).

8.Tightenthestopplate(Figure58).

Figure58).

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

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

Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.

Figure59

CheckingtheWheelHub SlottedNut

ServiceInterval:Aftertherst100hours

Every500hours

nuttoaligntheslot.Ifrequired,tightentothe nextsetofslots.

7.Installanewcotterpin.

Note:DoNotuseanti-seizeonwheelhub.

See

Figure60todeterminewhichslottednuthasbeen

installedontheunit.

Figure60

1.StyleA(blacknish)3.StyleB(yellowzinc)

2..03inch(.76mm)4..24inch(6mm)

•StyleA(blacknish):

Torquetheslottednutto211-260ft-lb(286-352 N-m).

Note:DoNotuseanti-seizeonwheelhub.

•StyleB(yellowzinc):

1.Removeanddiscardthecotterpin.

2.Torquetheslottednutto200ft-lb(271N-m).

AdjustingtheCasterPivot Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removethedustcapfromcasterandtightenlock

Figure62).

nut(

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

Important:Makesurethespringwashersare installedcorrectlyasshowninFigure62.

5.Installthedustcap(

Figure62).

3.Checkdistancefrombottomofslotinnutto insideedgeofhole.Twothreads(0.1inch)or lessshouldbeshowing.

Figure61

1.0.1inchmax2.Nomorethantwothreads (0.1inchmax)shouldbe showinghere.

4.Ifmorethantwothreads(0.1inch)areshowing removenutandinstallwasherbetweenhuband nut.

5.Torquetheslottednutto200ft-lb(271N-m).

6.Thentightennutuntilthenextsetofslotsline upwiththecrossholeinshaft.Donotloosen

Figure62

1.SpringWashers3.DustCap

2.LockNut

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwithclutches thatcontainabrakeshim.Whentheclutchbrakehas worntothepointwheretheclutchnolongerengages

consistently,theshimcanberemovedtoextendthe clutchlife.

Figure63

Note:DoNotremovethebrakepolefromthe

eldshell/armature.Thebrakepolehasworn tomatchthearmatureandneedstocontinueto matchaftertheshimisremovedtoensureproper braketorque.

1.Armature5.Brakespacer

2.Fieldshell6.Re-gapshim

3.Rotor7.Brakepole

4.Brakemountingbolt

RemovingtheClutchShim

1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake. Allowthemachinetocoolcompletelybeforestarting theseinstructions.

2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.

Figure65

1.Brakemountingbolt

B.Usingneedlenosepliers,orbyhand,takehold

ofthetabandremovetheshim(DoNotdiscard theshimuntilproperclutchfunctionhasbeen conrmed).

Figure66

1.Shim

Figure64

3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.

4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.

5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:

A.Loosenbothbrakemountingboltsone-halfto

onefullturnasshownbelow .

C.Usingapneumaticline,blowoutanydebris

fromunderthebrakepoleandaroundthebrake spacers.

D.Re-torqueeachbolt(M6x1)to10ft-lb(13N-m)

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

E.Usinga0.010inchthickfeelergauge,verifythat

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

1.Feelergauge

G008804

1.Feelergauge

CoolingSystem Maintenance

CleaningtheEngineScreen andEngineOilCooler

Figure67

ServiceInterval:Beforeeachuseordaily

Removeanybuild-upofgrass,dirtorotherdebrisfrom theoilcooler(Figure69).

Figure68

•Ifthegapislessthan0.010inch,thenreinstall theshimandreferencetheTroubleshooting section.

•Ifthegapissufcient,proceedtothesafety checkinstep

F.Performthefollowingsafetycheck:

a.Sitontheseatandstarttheengine.

b.MakesurethebladesDoNotengagewiththe

PTOswitch“off”andtheclutchdisengaged.

Iftheclutchdoesnotdisengage,reinstallthe shimandreferencetheTroubleshooting section.

c.EngageanddisengagethePTOswitch

tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.

Figure69

Beforeeachuseremoveanybuild-upofgrass,dirtor otherdebrisfromtheenginescreen.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine(

Figure70).

CleaningtheEngineCooling FinsandShrouds

ServiceInterval:Every100hours/Yearly(whichever

comesrst)

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removetheairintakescreen,recoilstarterandfan housing(Figure70).

4.Cleanthedebrisandgrassfromtheengineparts.

5.Installairintakescreen,recoilstarterandfanhousing (

Figure70).

Figure70

1.Engineguard4.Fanhousing

2.Engineairintakescreen

3.Bolt

5.Screw

CheckandCleantheHydraulic UnitShrouds

ServiceInterval:Beforeeachuseordaily

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisetheseatup.

4.Cleanthedebrisandgrassfromthehydraulicunit shrouds(

5.Lowertheseat.

Figure71).

Figure71

1.Hydraulicunitshrouds

BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst100hours

Every500hoursthereafter

Checktomakesurebrakeisadjustedproperly .This proceduremustbefollowedaftertherst100hoursor whenabrakecomponenthasbeenremovedorreplaced.

1.Drivethemachineontoalevelsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,waitforallmovingpartstostop, andremovethekey .

4.Raisethebackofthemachineupandsupportthe machinewithjackstands.

DANGER

Figure72

LeftHandBrakeShown

1.Cableanchor5.Caliper

2.Holdthreadedrodhere

3.Measure7.Threadedrod

4.Locknut8.Hub

6.Compressionspring

Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury.

•Usejackstandwhensupportingmachine.

•Donotusehydraulicjacks.

5.Removethereartiresfromthemachine.

6.Removeanydebrisfromthebrakearea.

7.Rotatethedrivewheelreleasehandletothereleased position.RefertotheUsingtheDriveWheel ReleaseV alvessectioninOperation.

8.Measuretheoveralllengthofthecompression spring.Thecorrectlengthshouldbebetween1-1/2 and1-9/16inches(3.8and4.0cm).Ifthespring lengthiswithinthisrange,noadjustmentisneeded. Ifitisnot,proceedtostep

9.Holdthethreadedrodendwithatoolandadjust thelocknutuntilthespringlengthisbetween1-1/2 and1-9/16inches(3.8and4.0cm)(

Figure72).Do Notallowthecabletoturnwhenthenutsarebeing loosened.

10.Disengagetheparkbrake.Turnthewheelhubby handinbothdirectionsrelativetothecaliper;no dragofthecaliperpadonthewheelhubisdesired.

11.Ifthereisnomovementbetweenthehubandthe caliperthenrepeattheadjustment(driverelease valvesmustbeinthereleasedpositiononthe hydros).

12.Afteradjustingthebrakesonbothsidesofthe mower,cyclethebrakehandleaminimumofsix timestoallowthecabletoseatintothesheathand mountingtabs.

13.Recheckthespringlength;engagetheparkbrake andrepeatsteps

8through11ifthelengthisnotin

thecorrectrange.

14.Rotatethedrivewheelreleasehandletothe

operatingposition.RefertotheUsingtheDrive WheelReleaseValvessectioninOperation.

15.Installthereartiresandtorquelugnutsbetween90 and95ft-lb(122and129N-m).

16.Removejackstands.

BeltMaintenance

G009036

InspectingtheBelts

ServiceInterval:Every50hours

Checkthebeltsforsquealingwhenthebeltisrotating, bladesslippingwhencuttinggrass,frayedbeltedges, burnmarksandcracksaresignsofawornmowerbelt. Replacethemowerbeltifanyoftheseconditionsare evident.

ReplacingtheMowerBelt

Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofawornmowerbelt.Replacethemowerbelt ifanyoftheseconditionsareevident.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Lowerthemowertothe3inch(76mm)heightof cut.

4.Removethebeltcovers(

1.Pushtabdown2.Removebeltcover

5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(

6.Removethebeltfromthemowerdeckpulleys.

Figure73).

Figure73

Figure74).

Figure74

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

10.Installthebeltguideontheidlerarmshownin Figure74.

11.Usingtheratchetinthesquarehole,installtheidler spring(Figure74).

Makesurethespringendsareseatedintheanchor grooves.

12.Installthebeltcovers(

armfortheratchet

7.Beltguide

Figure75).

7.Removethebeltguideonthespringloadedidlerarm shownin

8.Removetheexistingbelt.

9.Installthenewbeltaroundthemowerpulleysand theclutchpulleyundertheengine(Figure74).

Figure74.

Figure75

1.Positionthebeltcover3.Ensurethetabisunder

2.Slidebeltcoverunderthe sidecatches

themetalcatch

ReplacingtheHydraulicPump DriveBelt

1.DisengagethePTOandsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.

4.Raisethemachineandsupportitwithjackstands

Figure76).

(

Figure76

1.Idlerpulley

2.Clutchpulley6.Squareholeinidlerarm

3.Pumpdrivebelt7.Idlerspring

4.Righthandhydraulicpump pulley

5.Lefthandhydraulicpump 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; highandlow .Removetheboltstoadjusttheheightfor theoperator.

1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Loosentheboltsandangenutsinstalledinthe levers(

Figure77).

Figure78

4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslide themuntiltheyarealigned,thentightenthebolts

Figure78).

(

Figure77

1.Bolt

2.Handle4.Nut

3.Controllever

AdjustingtheMotionControl Linkage

Locatedoneithersideofthefueltank,belowtheseatare thepumpcontrollinkages.Rotatingthepumplinkage witha1/2inchwrenchallowsnetuningadjustments sothatthemachinedoesnotmoveinneutral.Any adjustmentsshouldbemadeforneutralpositioningonly .

WARNING

Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.

Keepngers,hands,andclothingclearofrotating componentsandhotsurfaces.

1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdeckto theground.

2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely .

3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushionof theseat.Theswitchisapartoftheseatassembly.

4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.

5.Startengine.Brakemustbeengagedandmotion

controlleversouttostartengine.Operatordoes

nothavetobeintheseatbecauseofthejumper wirebeingused.Runengineatfullthrottleand

releasebrake.

AdjustingtheMotionControl Damper

6.Runtheunitatleast5minuteswiththedrivelevers atfullforwardspeedtobringhydraulicoilupto operatingtemperature.

Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.

7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsby rotatingthedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepinreverse

Figure79).Movethemotioncontrolleverstothe

( reversepositionandwhileapplyingslightpressureto theleverallowthereverseindicatorspringstobring theleversbacktoneutral.Thewheelsmuststop turningorslightlycreepinreverse.

Thetopdampermountingboltcanbeadjustedtoobtain amoredesiredmotioncontrolleverresistance.See Figure80formountingoptions.

Figure80

RHMotionControlShown

1.Torquethelocknutto200in-lb(16.7ft-lb).Boltmust protrudepastendoflocknutaftertorque.

2.Leastresistance(softestfeel)

3.Damper

4.Mediumresistance(mediumfeel)

5.Mostresistance(rmestfeel)

Figure79

1.Doublenuts

8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.

9.Removethejackstands.

10.Raisethedeckandre-installtheheightofcutpin.

11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.

AdjustingtheMotionControl NeutralLockPivot

Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittothe neutrallockposition.SeeFigure81foradjustment options.

1.Loosenthejamnut.

2.Tightenorloosentheangednuttothedesiredfeel.

Formoreresistance,tightentheangednut.

Forlessresistance,loosentheangednut

3.Tightenjamnut.

HydraulicSystem Maintenance

ServicingtheHydraulic System

Figure81

1.Flangednut2.Jamnut

115W -50.

HYPR-OIL

HydraulicOilType:Toro hydraulicoilorMobil

Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.

EachHydraulicSystemOilCapacity:52ounces(1.5

l)persidewithlterchange

™

500

CheckingtheHydraulicOil

ServiceInterval:Every50hours—Checkthehydraulic

oillevel.

1.Positionthemachineonalevelsurface.

2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Allowtheengineandhydraulicsystemtocoolfor tenminutes.

Note:Theoillevelonthedipstickwillbeincorrect whentheoilischeckedandtheunitishot.

5.Movetheseatforward.

6.Cleantheareaaroundthedipsticksofhydraulic systemreservoirs(

7.Removeonedipstickfromthehydraulicreservoir

Figure82).

(

8.Wipethedipstickoffandthreadthedipstickinto thereservoir.

9.Removethedipstickandlookattheend( Iftheoillevelisattheaddmark,slowlypouronly enoughoilintothehydraulicreservoirtoraisethe leveltothefullorHline.

Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewiththeoilbelowtheaddmark.

10.Installthedipstick.

11.Repeatprocedurefortheoppositedipstick.

Figure82).

G015459

ReplacingtheHydraulicFiltersand HydraulicOil

ServiceInterval:Every250hours—Changethe

hydraulicltersandhydraulicoil whenusingMobil1oil.

Every500hours—Changethe hydraulicltersandhydraulicoil whenusingToro hydraulicoil

Toreplacethehydraulicoil,theltersneedtobe removed.Replacebothatthesametime.

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemachineandsupportitwithjackstands

Figure83).

(

HYPR-OIL

™

500

Figure82

Eitherdipstickwillbeusedinthemachine

1.Full3.H–meanshighlevel

2.Add4.Dipsticklocationsunder seat

WARNING

Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury.

•Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.

•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.

•Usecardboardorpapertondhydraulic leaks.

•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.

Figure83

1.Jackstands

4.Removeboththemowerbeltandthepumpdrive belt.Thiswillpreventoilgettingonthebelts.Refer toBeltsintheMaintenanceSection.

5.Placeadrainpanunderthelter,removetheold lterandwipethesurfaceclean(Figure84).

•Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.

G008968

Figure84

BottomViewofMachine

1.Filterlocations

6.Applyathincoatofhydraulicoiltotherubber gasketonthereplacementlter(Figure84).

7.Installthereplacementhydrauliclter.

8.Installthepumpdrivebeltandthemowerbelt.

9.Removethejackstandsandlowerthemachine

Figure83).

(

10.Addoiltothehydraulicreservoirandcheckforany leaks.

2.Hydrauliclter

MowerDeck Maintenance

LevelingtheMowerDeck

SettingUptheMachine

Note:Ensurethemowerdeckisleveledbefore

matchingtheheight-of-cut(HOC).

1.Positionmoweronaatsurface.

2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

4.Checktirepressureofthedrivetires.Ifneeded, adjustto13psi(90kPa)

5.Positionthemowertothe3inch(76mm) height-of-cutposition.

DeckLeveling

1.Positionthemoweronaatsurface.

2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

3.Checkthetirepressureinthedrivetires.Proper inationpressurefortiresis13psi(90kPa).Adjust ifnecessary.

11.Cleanupanyspilledoil.

12.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.

13.Checktheoillevelwhiletheoiliscold.

14.Ifrequired,addoiltothehydraulicreservoir.Do notoverll.

4.Positionthetransportlockinthelatchingposition.

5.Pushthedeckliftpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(

Figure85).

G017027

Figure85

10.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

1.Deckliftpedal

2.Heightofcutpin

3.Transportlock

6.Inserttheheightadjustmentpinintothe3inch(7.6 cm)cuttingheightlocation.

7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.

8.Raisethedischargechute.

9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA). Themeasurementshouldread3inches(7.6mm) (Figure86).

Figure87

1.Adjustmentnut3.Reardeckadjustment

2.JamNut4.Frontdeckadjustment

11.Ifthefrontdecklinksdonothaveenoughadjustment toachieveaccuratecutheight,thesinglepoint adjustmentcanbeutilizedtogainmoreadjustment.

12.Toadjustthesinglepointsystem,loosenthetwo boltsatthebottomoftheheightofcutplate.Refer

Figure88.

1.3inches(7.6cm)atAis correct

2.31/4inches(8.3cm)atB iscorrect

Figure86

3.Measureherefromthe bladetiptohardsurface

4.MeasureatAandBon bothsides

g017029

Figure88

g017036

1.Boltsatthebottomoftheheight-of-cutplate

Note:Inmostconditions,thebackbladetipshould beadjusted1/4inch(6.4mm)higherthanthefront.

15.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(PositionB).The measurementshouldread31/4inches(8.3cm)

Figure86).

(

16.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(

Figure87).

Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.

17.Measureuntilallfoursidesarethecorrectheight. Tightenallthejamnutsonthedeckliftarm assemblies.

18.Lowerdischargechute.

13.Ifthedeckistoolow ,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.Ifthedeck istoohigh,loosenthesinglepointadjustmentbolt byrotatingitcounterclockwise(

Figure89).

Note:Loosenortightenthesinglepointadjustment boltenoughtomovetheheight-of-cutplate mountingboltsatleast1/3thelengthoftheavailable travelintheirslots.Thiswillregainsomeupand downadjustmentoneachofthefourdecklinks.

Figure89

1.Singlepointadjustmentbolt

14.Tightenthetwoboltsatthebottomoftheheightof cutplate(Figure88).Torqueto27-33ft-lb(37-45 N-m).

ServicingtheCuttingBlades

Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.

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

DANGER

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

•Inspectthebladeperiodicallyforwearor damage.

•Replaceawornordamagedblade.

CheckingforBentBlades

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure91).Measurefromalevelsurface tothecuttingedge,positionA,oftheblades

Figure91).Notethisdimension.

(

BeforeInspectingorServicingthe Blades

Parkthemachineonalevelsurface,disengagetheblade controlswitch(PTO),andsettheparkingbrake.Turn theignitionkeytoOff.Removethekey.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure90).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.

2.Inspecttheblades,especiallythecurvedarea (Figure90).Ifyounoticeanydamage,wear,oraslot forminginthisarea( newblade.

Figure90),immediatelyinstalla

Figure91

1.Measureherefromblade tohardsurface

2.PositionA

4.Rotatetheoppositeendsofthebladesforward.

5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin

3and4mustnotexceed1/8inch(3mm).If

steps thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.

WARNING

Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.

•Alwaysreplacebentordamagedbladewith anewblade.

Figure90

1.CuttingEdge3.Wear/slotForming

2.CurvedArea4.Crack

•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.

RemovingtheBlades

Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum

performanceandcontinuedsafetyconformanceof themachine,usegenuineTOROreplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.

WARNING

InstallingtheBlades

1.Installthebladeontothespindleshaft(Figure94).

Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.

Contactwithasharpbladecancauseseriousinjury.

Wearglovesorwrapsharpedgesofthebladewith arag.

1.Holdthebladeendusingaragorthickly-padded glove.

2.Removethebladebolt,springdiskandbladefrom thespindleshaft(

Figure94).

SharpeningtheBlades

WARNING

Whensharpeningblade,piecesofbladecouldbe thrownandcauseseriousinjury.

Wearpropereyeprotectionwhensharpeningblade.

1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure92).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.

2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead

Figure94).Torquethebladeboltto85-110ft-lb

( (115-150N-m).

Figure94

1.SailAreaofBlade

2.Blade

3.SpringDisk

4.BladeBolt

5.ConeT owardsBoltHead

Figure92

1.Sharpenatoriginalangle

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure93).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(

Figure94).Repeatthis

procedureuntilthebladeisbalanced.

Figure93

1.Blade2.Balancer

RemovingtheMowerDeck

Beforeservicingorremovingthemowerdeck,thespring loadeddeckarmsmustbelockedout.

WARNING

Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.

DoNotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.

1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.

2.Removetheheightadjustmentpinandlowerthe decktotheground.

3.Placetheheightadjustmentpininthe3inch(7.6cm) cuttingheightlocation.Thislocksthedeckliftarms inthelowestpositionwhenthedeckisremovedand thestoredenergyinthedeckspringisreleased.

4.Removethebeltcovers.

5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(

Figure95).

6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(

Figure95).

Figure95

1.Clutchpulley5.Squareholeintheidler

2.Mowerbelt6.Idlergreasezerk

3.Springloadedidlerpulley

4.Ratchet

armfortheratchet

7.Beltguide

7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure96.

g015594

6 2

Figure97

Figure96

1.Rightstabilizer

2.Deckstrut(rightsideshown)

3.Removethereardeckliftattachmentshoulderboltandnut.

4.Removethefrontdeckliftattachmentshoulderboltandnut.

8.Raisethedeckstrutsandsecurethemintheup position.Slidethedeckouttotherightsideofthe machine.

ReplacingtheGrassDeector

WARNING

Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator'sor bystander'sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.

1.Bolt

2.Spacer6.GrassDeector

3.Locknut

4.Spring

5.Springinstalled

7.Jhookendofspring

2.Placespacerandspringontograssdeector.Place oneJendofspringbehinddeckedge.

Note:MakesureoneJendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown

Figure97.

3.Installboltandnut.PlaceoneJhookendofspring aroundgrassdeector(Figure97).

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

Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.

1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure97). Removedamagedorworngrassdeector.

Cleaning

Storage

CleaningUndertheMower

ServiceInterval:Beforeeachuseordaily

1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.

2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.

3.Raisethemowertothetransportposition.

WasteDisposal

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

CleaningandStorage

1.Disengagethepowertakeoff(bladecontrolswitch (PTO),settheparkingbrake,andturntheignition keytoOff.Removethekey.

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

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

3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.

4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.

5.Greasethemachine;refertoGreasingand LubricationintheMaintenanceSection.

6.Changethecrankcaseoil;refertoServicingthe EngineOilintheMaintenanceSection.

7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.

8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.

9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.

10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.

Note:Runthemachinewiththebladecontrol switch(PTO)engagedandtheengineathighidlefor 2to5minutesafterwashing.

11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.

12.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachineforstorage asfollows:

A.Addapetroleumbasedstabilizer/conditioner

tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandused atalltimes.

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.Repair orreplaceanypartthatisdamaged.

14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.

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

Troubleshooting

Problem

Starterdoesnotcrank

Enginewillnotstart,startshard,orfails tokeeprunning

PossibleCauseCorrectiveAction

1.Bladecontrolswitch(PTO)isengaged.1.Movebladecontrolswitch(PTO)to

2.Parkingbrakeisnoton.

3.Driveleversarenotinneutrallock position.

4.Operatorisnotseated.4.Sitontheseat.

5.Batteryisdead.

6.Electricalconnectionsarecorrodedor loose.

7.Fuseisblown.

8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.

1.Fueltankisempty.

2.Fuelshutoffvalveisclosed.2.Openthefuelshutoffvalve.

3.Oillevelinthecrankcaseislow.

4.Thethrottleandchokearenotinthe correctposition.

5.Dirtinfuellter .5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel system.

7.Aircleanerisdirty.

8.Seatswitchisnotfunctioningproperly .8.Checktheseatswitchindicator.

9.Electricalconnectionsarecorroded, looseorfaulty.

10.Relayorswitchisdefective.10.ContactanAuthorizedServiceDealer.

11.Faultysparkplug.

12.Sparkplugwireisnotconnected.12.Checkthesparkplugwireconnection.

disengaged.

2.Settheparkingbrake.

3.Ensurethedriveleversareinthe neutrallockposition.

5.Chargethebattery .

6.Checktheelectricalconnectionsfor goodcontact.

7.Replacefuse.

1.Fillthefueltank.

3.Addoiltothecrankcase.

4.Besurethethrottlecontrolismidway betweenthe“SLOW”and“FAST” positions,andthechokeisinthe“ON” positionforacoldengineorthe“OFF” positionforawarmengine.

6.ContactanAuthorizedServiceDealer.

7.Cleanorreplacetheaircleaner element.

Replaceseatifneeded.

9.Checktheelectricalconnections forgoodcontact.Cleanconnector terminalsthoroughlywithelectrical contactcleaner,applydielectricgrease andreconnect.

11.Clean,adjustorreplacesparkplug.

Enginelosespower.

Engineoverheats.

Mowerpullsleftorright(withleversfully forward)

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Aircleanerisdirty.

3.Oillevelinthecrankcaseislow.

4.Coolingnsandairpassagesabove theengineareplugged.

5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.

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

7.Dirt,water,orstalefuelisinthefuel system.

1.Engineloadisexcessive.1.Reducethegroundspeed.

2.Oillevelinthecrankcaseislow.

3.Coolingnsandairpassagesabove theengineareplugged.

1.Trackingneedsadjustment1.Adjustthetracking.

2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.

2.Cleantheaircleanerelement.

3.Addoiltothecrankcase.

4.Removetheobstructionfromthe coolingnsandairpassages.

7.ContactanAuthorizedServiceDealer.

2.Addoiltothecrankcase.

3.Removetheobstructionfromthe coolingnsandairpassages.

Problem

PossibleCauseCorrectiveAction

Machinedoesnotdrive.

Abnormalvibration.

Unevencuttingheight.

1.Bypassvalvesisnotclosedtight.1.Tightenthebypassvalves.

2.Pumpbeltisworn,looseorbroken.

3.Pumpbeltisoffapulley.3.Changethebelt.

4.Brokenormissingidlerspring.4.Replacethespring.

5.Hydraulicoillevelislowortoohot.5.Addhydraulicoiltoreservoirsorletit

1.Cuttingblade(s)is/arebentor unbalanced.

2.Blademountingboltisloose.2.Tightentheblademountingbolt.

3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.

4.Looseenginepulley,idlerpulley,or bladepulley.

5.Enginepulleyisdamaged.

6.Bladespindleisbent.

7.Motormountislooseorworn.

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

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

3.Mowerdeckisnotlevel.

4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.

5.Tirepressureisnotcorrect.5.Adjustthetirepressure.

6.Bladespindlebent.

2.Changethebelt.

cooldown.

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

5.ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

3.Levelmowerdeckfromside-to-side andfront-to-rear.

6.ContactanAuthorizedServiceDealer.

Bladesdonotrotate.

Clutchwillnotengage.

1.Mowerdeckbeltisworn,looseor broken.

2.Mowerdeckbeltisoffpulley .

3.Pumpdrivebeltisworn,looseor broken.

4.Brokenormissingidlerspring.4.Replacethespring.

1.Fuseisblown.

2.Lowvoltagesupplyattheclutch.

3.Damagedcoil.3.Replaceclutch.

4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor

5.Rotor/armatureairgapistoolarge.

1.Installnewdeckbelt.

2.Installmowerdeckpulleyandcheck theidlerpulley,idlerarmandspringfor correctpositionandfunction.

3.Checkthebelttensionorinstallnew belt.

1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.

2.Checkcoilresistance,battery charge,chargingsystem,andwiring connectionsandreplaceifnecessary.

electricalsystem.Cleanconnector contacts.

5.Removeshimorreplaceclutch.

Schematics

WireDiagram(Rev.A)

Notes:

TheToroTotalWarranty

Landscape Contractor Equipment(LCE)

ConditionsandProductsCovered

TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheT oroProductslistedbelowifdefectiveinmaterialsor workmanship.

Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:

ProductsWarrantyPeriod

HeavyDutyWalkPowerMowers– Residentialuse

HeavyDutyWalkPowerMowers– Commercialuse

Mid-SizeWalk-BehindMowers

•Engine2years

GrandStand

Mowers

•KawaskiEngine2years

•KohlerEFIEngine3years

•Frame

ZMaster

2000SeriesMowers

•Engine2years

•Frame

ZMaster

3000SeriesMowers

•Engine2years

•Frame

ZMaster

5000and6000Series

Mowers

•KawaskiEngine2years

•KohlerEngine2years

•KohlerEFIEngine3years

•Frame

ZMaster

7000SeriesMowers

•Engine2years

•Frame

AllMowers

•Attachments2years

Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone

locationisconsideredcommercialuseandthecommercialwarrantywouldapply.

SomeenginesusedonToroLCEProductsarewarrantedbytheenginemanufacturer.

Whicheveroccursrst.

LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe

tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin

normaluse,itwillberepairedorreplacedunderwarrantyatnocostforpartsandlabor.Frame

failureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosionarenotcovered.

Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.

2years

1year

2years

5yearsor1,200hours

Lifetime(originalowneronly)

4yearsor500hours

Lifetime(originalowneronly)

5yearsor1,200hours

Lifetime(originalowneronly)

5yearsor1,200hours

Lifetime(originalowneronly)

4yearsor1,200hours

Lifetime(originalowneronly)

InstructionsforObtainingWarrantyService

IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:

1.Contactyoursellertoarrangeserviceoftheproduct.Ifforanyreason itisimpossibleforyoutocontactyourseller,youmaycontactany ToroAuthorizedDistributortoarrangeservice.

2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.

3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:

RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1 196 001-952-948-4650

SeeattachedDistributorList.

OwnerResponsibilities

YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator'sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.

ItemsandConditionsNotCovered

Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:

•ThebatteryintheseproductsarenotwarrantedbyT oro,contact

yourAuthorizedT oroServiceDealerorthebatterymanufacturerfor warranty.

•Costofregularmaintenanceserviceorwearparts,suchaslters,

fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.

•Anyproductorpartwhichhasbeenalteredormisusedandrequires

replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.

•Repairsnecessaryduetoimproperfuel,contaminantsinthefuel

system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.

•Thebatteryandanycomponentcoveredbyaseparatemanufacturers

warranty.

•Pickupanddeliverycharges.

Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingT oroapprovedreplacementparts.

GeneralConditions

Thepurchaseriscoveredbythenationallawsofeachcountry .Therights towhichthepurchaserisentitledwiththesupportoftheselawsarenot restrictedbythiswarranty .

374-0273RevB

Toro Z Master 74941CP, Z Master 74943CP, Z Master 74945CP Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual