Toro Z Master Professional 7500-D Series Riding Mower, With 72in TURBO FORCE Side Discharge Mower Riding Product Operator's Manual

Form No. 3434-326 Rev A
Z Master® Professional 7500-D
Series Riding Mower
with 60in or 72in TURBO FORCE® Mower
Model No.
Model No.
Model No.
Model No.
Register at www.Toro.com.
Original Instructions (EN)
72028—Serial No.
72029—Serial No.
72074—Serial No.
72076—Serial No.
400000000 and Up
400000000 and Up
400000000 and Up
400000000 and Up
*3434-326* A
Introduction
It is a violation of California Public Resource Code
Section 4442 or 4443 to use or operate the engine on
any forest-covered, brush-covered, or grass-covered
land unless the engine is equipped with a spark
arrester, as defined in Section 4442, maintained in
effective working order or the engine is constructed,
equipped, and maintained for the prevention of fire.
This rotary-blade, riding lawn mower is intended to be
used by professional, hired operators. It is designed
primarily for cutting grass on well-maintained lawns
on residential or commercial properties. Using this
product for purposes other than its intended use could
prove dangerous to you and bystanders.
The enclosed engine owner's manual is supplied
for information regarding the US Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance,
and warranty. Replacements may be ordered through
the engine manufacturer.
Read this information carefully to learn how to operate
and maintain your product properly and to avoid
injury and product damage. You are responsible for
operating the product properly and safely.
Please refer to the engine manufacturer’s information
included with the machine.
Visit www.Toro.com for product safety and operation
training materials, accessory information, help finding
a dealer, or to register your product.
Gross or Net Torque: The gross or net torque
of this engine was laboratory rated by the engine
manufacturer in accordance with the Society of
Automotive Engineers (SAE) J1940 or J2723. As
configured to meet safety, emission, and operating
requirements, the actual engine torque on this class
of mower will be significantly lower. Please refer to
the engine manufacturer’s information included with
the machine.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model
and serial numbers of your product ready. Figure 1
identifies the location of the model and serial numbers
on the product. Write the numbers in the space
provided.
Important: With your mobile device, you can
scan the QR code (if equipped) on the serial
number decal to access warranty, parts, and other
product information.
Go to www.Toro.com to view specifications on your
model.
WARNING
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
Battery posts, terminals, and related
accessories contain lead and lead
compounds, chemicals known to
the State of California to cause
cancer and reproductive harm. Wash
hands after handling.
Use of this product may cause exposure
to chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.
g235670
Figure 1
1. Model and serial number location
Model No.
Serial No.
This manual uses 2 words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
© 2019—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA
All Rights Reserved
Contents
Fuel System Maintenance ................................... 45
Draining the Fuel Filter/Water Separator ........... 45
Replacing the Water Separator ........................ 45
Checking the Fuel Lines and
Connections.................................................. 45
Electrical System Maintenance ........................... 46
Electrical System Safety ................................... 46
Servicing the Battery......................................... 46
Servicing the Fuses .......................................... 47
Drive System Maintenance .................................. 48
Checking the Seat Belt ..................................... 48
Adjusting the Tracking ...................................... 48
Checking the Tire Pressure............................... 49
Checking the Wheel Lug Nuts........................... 49
Adjusting the Caster-Pivot Bearing ................... 49
Servicing the Gearbox ...................................... 50
Cooling System Maintenance .............................. 51
Cooling System Safety ..................................... 51
Checking the Engine-Coolant Level.................. 51
Cleaning the Radiator ....................................... 51
Changing the Engine Coolant ........................... 52
Brake Maintenance ............................................. 53
Adjusting the Parking Brake.............................. 53
Belt Maintenance ................................................ 54
Inspecting the Belts .......................................... 54
Replacing the Mower Belt ................................. 54
Checking the Alternator-Belt Tension................ 55
Controls System Maintenance ............................. 56
Adjusting the Control-Handle Position .............. 56
Adjusting the Motion-Control Linkage ............... 56
Adjusting the Motion-Control Damper ............... 57
Hydraulic System Maintenance ........................... 58
Hydraulic System Safety................................... 58
Servicing the Hydraulic System ........................ 58
Mower Deck Maintenance.................................... 60
Blade Safety ..................................................... 60
Servicing the Cutting Blades ............................. 60
Leveling the Mower Deck.................................. 63
Replacing the Grass Deflector .......................... 66
Cleaning .............................................................. 67
Cleaning the Engine and Exhaust System
Area .............................................................. 67
Cleaning the Machine and Mower
Deck.............................................................. 67
Disposing of Waste........................................... 67
Storage ................................................................... 68
Storage Safety.................................................. 68
Cleaning and Storage ....................................... 68
Troubleshooting ...................................................... 69
Schematics ............................................................. 71
Safety ....................................................................... 4
Safety Alert Symbol ............................................ 4
General Safety ................................................... 4
Slope Indicator ................................................... 5
Safety and Instructional Decals .......................... 6
Product Overview ................................................... 13
Controls ........................................................... 14
Horizon Display Monitor ................................ 14
Specifications .................................................. 16
Attachments/Accessories ................................. 16
Before Operation ................................................. 17
Before Operation Safety ................................... 17
Adding Fuel ...................................................... 18
Performing Daily Maintenance.......................... 19
Breaking in a New Machine .............................. 19
Using the Rollover Protection System
(ROPS) ......................................................... 19
Using the Safety-Interlock System .................... 20
Positioning the Seat.......................................... 21
Unlatching the Seat .......................................... 21
Changing the Seat Suspension......................... 21
During Operation ................................................. 22
During Operation Safety ................................... 22
Operating the Parking Brake............................. 24
Operating the Mower Blade-Control Switch
(PTO) ............................................................ 25
Starting the Engine ........................................... 25
Shutting Off the Engine..................................... 26
Using the Motion-Control Levers....................... 26
Driving the Machine .......................................... 27
Using the Side Discharge ................................. 28
Adjusting the Height of Cut ............................... 28
Adjusting the Anti-Scalp Rollers........................ 29
Adjusting the Skids ........................................... 30
Adjusting the Flow Baffle Knob ......................... 30
Positioning the Flow Baffle................................ 31
Operating with the Overheat Sensor ................. 32
Operating Tips ................................................. 33
After Operation .................................................... 34
After Operation Safety ...................................... 34
Using the Drive-Wheel Release Valves ............. 34
Transporting ..................................................... 34
Maintenance ........................................................... 37
Maintenance Safety.......................................... 37
Recommended Maintenance Schedule(s) ........... 38
Lubrication .......................................................... 40
Greasing the Machine....................................... 40
Lubricating the Drive U-Joints and Splined
Slip Joint ....................................................... 40
Greasing the Caster Pivots ............................... 41
Greasing the Caster-Wheel Hubs ..................... 41
Engine Maintenance ........................................... 42
Engine Safety ................................................... 42
Servicing the Air Cleaner .................................. 42
Servicing the Engine Oil.................................... 43
Inspecting the Engine-Valve Clearance ............ 44
3
General Safety
Safety
This machine is capable of amputating hands and feet
and of throwing objects. Toro designed and tested
this lawn mower to offer reasonably safe service;
however, failure to comply with safety instructions
may result in injury or death.
This machine has been designed in accordance with
ANSI B71.4-2017.
Safety Alert Symbol
• Read, understand, and follow all instructions and
warnings in the Operator’s Manual and other
training material, on the machine, engine, and
attachments. All operators and mechanics should
be trained. If the operator(s) or mechanic(s) can
not read this manual, it is the owner’s responsibility
to explain this material to them; other languages
may be available on our website.
This Safety Alert Symbol (Figure 2) is used both in
this manual and on the machine to identify important
safety messages which must be followed to avoid
accidents.
This symbol means: ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
• Only allow trained, responsible, and physically
capable operators that are familiar with the safe
operation, operator controls, and safety signs and
instructions to operate the machine. Never let
children or untrained people operate or service the
equipment. Local regulations may restrict the age
of the operator.
g000502
Figure 2
Safety Alert Symbol
• Always keep the roll bar in the fully raised and
The safety alert symbol appears above information
which alerts you to unsafe actions or situations and
will be followed by the word DANGER, WARNING, or
CAUTION.
locked position and use the seat belt.
• Do not operate the machine near drop-offs,
ditches, embankments, water, or other hazards, or
on slopes greater than 15 degrees.
DANGER: Indicates an imminently hazardous
situation which, if not avoided, Will result in death or
serious injury.
• Do not put your hands or feet near moving
components of the machine.
• Never operate the machine with damaged guards,
WARNING: Indicates a potentially hazardous situation
which, if not avoided, Could result in death or serious
injury.
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, May result in minor or moderate
injury.
• Stop the machine, shut off the engine, and remove
the key before servicing, fueling, or unclogging
the machine.
This manual uses two other words to highlight
information. Important calls attention to special
mechanical information and Note emphasizes general
information worthy of special attention.
4
Slope Indicator
g011841
Figure 3
You may copy this page for personal use.
1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of
hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line
to match the recommended slope.
2. Align this edge with a vertical surface, a tree, building, fence pole, etc.
3. Example of how to compare slope with folded edge
5
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or missing.
decalbatterysymbols
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
6. Keep bystanders away
from the battery.
2. No fire, open flame, or
smoking
7. Wear eye protection;
explosive gases can
cause blindness and other
injuries.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection.
8. Battery acid can cause
blindness or severe burns.
9. Flush eyes immediately
with water and get medical
help fast.
5. Read the Operator's
Manual.
decal99-8936
99-8936
1. Machine speed
4. Neutral
2. Fast
3. Slow
5. Reverse
10. Contains lead; do not
discard
decal106-5517
106-5517
decaloemmarkt
1. Warning—do not touch the hot surface.
Manufacturer's Mark
1. Indicates the blade is identified as a part from the original
machine manufacturer.
decal58-6520
58-6520
1. Grease
decal93-6687
93-6687
1. Do not step here.
6
decal112-9028
112-9028
1. Warning—stay away from moving parts; keep all guards
and shields in place.
decal116-5988
116-5988
1. Parking brake—engaged
2. Parking
brake—disengaged
decal107-3069
107-3069
1. Warning–there is no rollover protection when the roll bar is
down.
2. To avoid injury or death from a rollover accident, keep the
roll bar in the raised and locked position and wear the seat
belt. Lower the roll bar only when absolutely necessary; do
not wear the seat belt when the roll bar is down.
3. Read the Operator's Manual; drive slowly and carefully.
decal116-8283
116-8283
1. Warning—read the Operator's Manual for instructions on
torquing the blade bolt/nut to 75 to 81 N∙m (55 to 60 ft-lb).
decal117-3276
decal109-6036
117-3276
109-6036
Rear Discharge Machines Only
1. Read the Operator’s Manual.
2. Remove the key and read the instructions before servicing
or performing maintenance.
3. Height of cut
7
1. Engine coolant under
pressure
3. Warning—do not touch the
hot surface.
2. Explosion hazard—read
the Operator's Manual.
4. Warning—read the
Operator's Manual.
Side Discharge Mowers Only
decal126-6464
126-6464
1. Thrown object
hazard—keep bystanders
away.
3. Cutting/dismemberment
hazard of hand or foot,
mower blade—stay away
from moving parts; keep
all guards and shields in
place.
2. Thrown objects hazard,
mower—do not operate
without the deflector,
discharge cover, or grass
collection system in place.
decal126-8383
126-8383
Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum
recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as
well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on
that day and at that site. Changes in the terrain can result in a change in slope operation for the machine.
1. Warning—read the Operator’s Manual; do not operate this
machine unless you are trained; wear hearing protection.
4. Runover/backover hazard—do not carry passengers; look
behind you when mowing in reverse.
2. Cutting/dismemberment hazard of the hand, mower blade;
entanglement hazard of the hand, belt—stay away from
moving parts; keep all guards and shields in place.
5. Thrown object hazard—keep bystanders away.
3. Ramp hazard—do not use dual ramps when loading onto a
6. Tipping hazard—do not use the machine near drop-offs or
trailer; use 1 ramp wide enough for the machine; use a ramp
on slopes greater than 15°; only operate across slopes less
with a slope less than 15°; back up the ramp when loading the
than 15°.
machine and drive forward off the ramp when unloading.
8
For Models with 183 cm (72-inch) Decks with Side
Discharge
decal126-9276
126-9276
1. Belt routing
decal126-9275
126-9275
decal126-9278
126-9278
1. Engine—Off
4. Push the bottom of the button to lower the deck.
2. Engine—On
5. Push the top of the button to raise the deck.
3. Engine—Start
9
decal126-9279
126-9279
1. Read the instructions before servicing or performing
maintenance to the machine.
2. Time interval
7. Check the jackshaft-fluid level.
8. Grease the deck-drive PTO; refer to the Operator's Manual
for further instructions.
9. Check the air cleaner.
3. Check the engine-oil level.
4. Check the coolant level; refer to the Operator's Manual for
further instructions.
5. Check the tire pressure (2 locations).
10. Grease the idler pivot; refer to the Operator's Manual for
further instructions
11. Grease the front caster wheel bearings (2 locations); refer to
the Operator's Manual for further instructions.
6. Check hydraulic-fluid level; refer to the Operator's Manual
for further instructions.
12. Grease the front caster pivots (2 locations); refer to the
Operator's Manual for further instructions.
decal126-9280
126-9280
For Models with 152 cm (60-inch) or 183 cm (72-inch)
Decks with Rear Discharge
1. Belt routing
decal127-0326
127-0326
1. Read the Operator's
Manual.
decal126-9351
126-9351
1. Chassis (15 A)
3. Main (25 A)
2. Accessory (15 A)
4. Power point (15 A)
2. Height of cut
10
3. Remove the key and
read the Operator's
Manual before performing
maintenance.
Side Discharge Mowers Only
Rear Discharge Mowers Only
decal135-0664
135-0664
1. Thrown object
hazard—keep bystanders
away.
decal131-1180
131-1180
2. Cutting/dismemberment
hazard of hands and
feet—stay away from
moving parts; keep all
guards and shields in
place.
1. Read the Operator's Manual. (A) Short, light grass; dry
conditions; maximum dispersion; (B) Bagging setting; (C)
Tall, dense grass; wet conditions; maximum ground speed
decal135-0328
135-0328
1. Torque the wheel lug nuts
to 129 N∙m (95 ft-lb).
2. Read and understand
the Operator's Manual
before performing any
maintenance; check the
torque after the first 100
hours, then every 500
hours, thereafter.
decal135-0679
135-0679
1. Rotating driveline hazard/entanglement hazard; belt—stay
away from moving parts; keep all guards and shields in
place.
11
decal135-1432
135-1432
decal135-2837
135-2837
1. Read the Operator’s Manual for more information; Use
red Toro wet-clutch transmission fluid; do not use green
hydraulic fluid.
decal133-8062
133-8062
12
Product Overview
g227303
Figure 4
1. Height-of-cut pin
7. Motion-control lever
2. Parking-brake lever
8. Fuel-tank cap
9. Anti-scalp roller
3. Monitor/controls
4. Roll bar
5. Engine screen
10. Skid
11. Caster wheel
6. Audible alarm and power point
12. Mower deck
13
Controls
Become familiar with all the controls before you start
the engine and operate the machine.
Control Panel
g228164
Figure 6
Horizon Display Monitor
g225792
Figure 5
1. Horizon display monitor
3. Key switch
2. Deck-lift switch
4. Blade-control switch
(power takeoff)
1. Screen
2. LED status light
3. Buttons
Information Screen
Horizon Display Monitor
The information screen displays information relative
to machine operation; refer to the Software Guide for
more information.
Refer to the Software Guide for detailed information
explaining the operator interface that allows you to
access information, reset counters, modify system
settings, and troubleshoot the equipment.
Buttons
The multi-functional buttons are located at the bottom
of the panel. The icons displayed on the information
screen above the buttons indicate the current function.
The buttons allow you to select the engine speed and
navigate through system menus.
Refer to the Software Guide for more information.
LED Status Light
The LED status light is multi-colored to indicate the
system status and is located on the right side of the
panel. During startup, the LED illuminates red to
orange to green to verify functionality.
• Solid green—indicates normal operating activity
• Blinking red—indicates an active fault
• Blinking green and orange— indicates that a
clutch reset is required
Refer to the Software Guide for more information.
Alarm
If an error occurs, an error message displays, the LED
turns red, and the alarm sounds audibly as follows:
14
Blade-Control Switch (Power
Takeoff)
• A fast chirp sound indicates critical errors.
• A slow chirping sound indicates less critical errors,
such as required maintenance or service intervals.
The blade-control switch (PTO) engages and
disengages power to the mower blades (Figure 5).
Note: During startup, the alarm sounds briefly to
verify functionality.
The LCD indicator appears on the information screen
when the PTO switch is disengaged.
Refer to the Software Guide for more information.
Note: Machines equipped with the Horizon Display
Monitor have a clutch saver, which allows the throttle
to automatically reduce the engine speed when
you disengage the PTO switch. Engaging and
disengaging the PTO switch changes the engine
throttle between MOW and TRANSPORT mode.
Hour Meter
The hour meter records the number of hours the
engine has operated. It operates when the engine
is running. Use these times for scheduling regular
maintenance (Figure 5).
Refer to the Software Guide for more information.
Note: The system allows you to start the machine
with the PTO switch engaged, but does not engage
the blades. Engaging the PTO requires you to reset
the PTO switch by disengaging, then engaging it.
Key Switch
Deck-Lift Switch
Use this switch to start the engine. It has 3 positions:
START , RUN, and OFF.
Press the switch rearward to raise the deck.
Hours are displayed in Engine-Off screen or in the
Engine Hour Counter menu.
Press the switch forward to lower the deck.
Note: The LCD indicators appear when each control
meets the “safe to start” mode (e.g., the indicator
turns on when you are in the seat.)
Motion-Control Levers
Note: The engine ECU controls the glow plugs during
cold starts. If the coolant temperature is too low, the
glow symbol displays on the monitor and the starter
does not crank when you turn the engine to the START
position. The glow plugs activate in the ON or START
position. Once the glow has been on long enough
for the current temperature, the glow symbol on the
monitor disappears and the engine cranks when
turned to the START position.
Use the motion-control levers to drive the machine
forward, reverse, and turn either direction (Figure 4).
Neutral-Lock Position
Note: The system allows you to start the machine the
Move the motion-control levers outward from the
center to the NEUTRAL-LOCK position when exiting
the machine (Figure 21). Always position the
motion-control levers into the NEUTRAL-LOCK position
when you stop the machine or leave it unattended.
with the PTO switch engaged, but does not engage
the blades. You must reset the PTO to engage the
PTO.
Parking-Brake Lever
Whenever you shut off the engine, engage the parking
brake to prevent accidental movement of the machine.
Throttle Control
The throttle controls the engine speed, and there are
3 speeds: Maximum, Efficient, and Low.
Refer to the Software Guide for more information.
15
Specifications
Tread Width of Caster Wheels
(Center-to-Center of Tires)—Side Discharge
Machines
Overall Width—Side Discharge Machines
60-inch Deck
72-inch Deck
60-inch Deck
72-inch Deck
Without the deck
141.2 cm (55.6
inches)
152.4 cm (60
inches)
101.3 cm (39.9 inches)
120.7 cm (47.5 inches)
Deflector up
156 cm (61.4
inches)
186.4 cm (73.4
inches)
Deflector down
184.9 cm (72.8
inches)
215.6 cm (84.9
inches)
Tread Width of Caster Wheels
(Center-to-Center of Tires)—Rear Discharge
Machines
Overall Width—Rear Discharge Machines
60-inch Deck
72-inch Deck
168.2 cm (66.2 inches)
198.7 cm (78.2 inches)
Roll bar up or down
72-inch Deck
244.9 cm (96.4
inches)
253 cm (99.6
inches)
255.5 cm (100.6 inches)
Overall Height—All Machines
Roll bar up
182.4 cm (71.8 inches)
Roll bar down
129.5 cm (51 inches)
182.4 cm (71.8 inches)
Roll bar down
129.5 cm (51 inches)
84 cm (33.1 inches)
60-inch Deck
72-inch Deck
146.3 cm (57.6 inches)
154.7 cm (60.9 inches)
60-inch Deck
72-inch Deck
157.2 cm (61.9 inches)
157.2 cm (61.9 inches)
Attachments/Accessories
A selection of Toro approved attachments and
accessories is available for use with the machine
to enhance and expand its capabilities. Contact
your Authorized Service Dealer or authorized Toro
distributor or go to www.Toro.com for a list of all
approved attachments and accessories.
Overall Height—All Machines
Roll bar up
84 cm (33.1 inches)
Wheel Base (Center of Caster Tire to Center of
Drive Tire)—Rear Discharge Machines
Overall Length—Rear Discharge Machines
Roll bar up or down
72-inch Deck
Wheel Base (Center of Caster Tire to Center of
Drive Tire)—Side Discharge Machines
Overall Length—Side Discharge Machines
60-inch Deck
60-inch Deck
To ensure optimum performance and continued safety
certification of the machine, use only genuine Toro
replacement parts and accessories. Replacement
parts and accessories made by other manufacturers
could be dangerous, and such use could void the
product warranty.
Tread Width of Drive Wheels—All Machines
112 cm (44.1 inches)
16
Fuel Safety
Operation
Use extreme care when handling fuel.
Note: Determine the left and right sides of the
machine from the normal operating position.
DANGER
In certain conditions fuel is extremely
flammable and vapors are explosive.
Before Operation
A fire or explosion from fuel can burn you,
others, and cause property damage.
Before Operation Safety
• Fill the fuel tank outdoors on level ground,
in an open area, when the engine is cold.
Wipe up any fuel that spills.
General Safety
• Evaluate the terrain to determine what accessories
• Never refill the fuel tank or drain the
machine indoors or inside an enclosed
trailer.
and attachments are needed to properly and
safely perform the job. Only use accessories and
attachments approved by Toro.
• Do Not fill the fuel tank completely full.
Fill the fuel tank to the bottom of the filler
neck. The empty space in the tank allows
fuel to expand. Overfilling may result in
fuel leakage or damage to the engine or
emission system.
• Inspect the area where the equipment is to be
used and remove all rocks, toys, sticks, wires,
bones, and other foreign objects. These can
be thrown or interfere with the operation of the
machine and may cause personal injury to the
operator or bystanders.
• Wear appropriate personal protective equipment
• Never smoke when handling fuel, and stay
away from an open flame or where fuel
fumes may be ignited by spark.
such as safety glasses, substantial slip-resistant
footwear, and hearing protection. Tie back long
hair and avoid loose clothing and loose jewelry
which may get tangled in moving parts.
• Store fuel in an approved container and
keep it out of the reach of children.
CAUTION
• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add fuel
when engine is running or when the engine
is hot.
This machine produces sound levels in
excess of 85 dBA at the operator’s ear and
can cause hearing loss through extended
periods of exposure.
• If fuel is spilled, Do Not attempt to start
the engine. Move away from the area of
the spill and avoid creating any source of
ignition until fuel vapors have dissipated.
Wear hearing protection when operating
this machine.
• Check that the operator presence controls,
• Do Not operate without entire exhaust
system in place and in proper working
condition.
safety switches, and shields are attached and
functioning properly. Do not operate unless they
are functioning properly.
• Do not operate the mower when people, especially
children, or pets are in the area. Stop the machine
and attachment(s) if anyone enters the area.
• Do not operate the machine without the entire
grass collection system, discharge deflector,
or other safety devices in place and in proper
working condition. Grass catcher components
are subject to wear, damage and deterioration,
which could expose moving parts or allow objects
to be thrown. Frequently check for worn or
deteriorating components and replace them with
the manufacturer’s recommended parts when
necessary.
17
• Keep engine and engine area free from
DANGER
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate in
these areas.
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite fuel vapors. A fire or
explosion from fuel can burn you and others
and cause property damage.
• Always place fuel containers on the ground
away from your vehicle before filling.
• Do Not fill fuel containers inside a vehicle
or on a truck or trailer bed because interior
carpets or plastic truck bed liners may
insulate the container and slow the loss of
any static charge.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on the
ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a
portable container, rather than from a fuel
dispenser nozzle.
• If a fuel dispenser nozzle must be used,
keep the nozzle in contact with the rim of
the fuel tank or container opening at all
times until fueling is complete. Do Not use
a nozzle lock open device.
• Clean up oil and fuel spills and remove fuel soaked
debris.
• Allow the machine to cool before storing the
machine in any enclosure. Do Not store near
flame or any enclosed area where open pilot lights
or heat appliances are present.
Adding Fuel
Recommended Fuel
The engine runs on clean, fresh diesel fuel with
a minimum cetane rating of 40. Purchase fuel in
quantities that can be used within 30 days to ensure
fuel freshness.
Use summer-grade diesel fuel (No. 2-D) at
temperatures above -7°C (20°F) and winter-grade
diesel fuel (No. 1-D or No. 1-D/2-D blend) below
-7°C (20°F). Use of winter-grade diesel fuel at lower
temperatures provides lower flash point and pour
point characteristics, therefore easing startability and
lessening chances of chemical separation of the fuel
due to lower temperatures (wax appearance, which
may plug filters).
Using summer-grade diesel fuel above -7°C
(20°F) contributes toward longer life of the pump
components.
WARNING
Fuel is harmful or fatal if swallowed.
Long-term exposure to vapors has caused
cancer in laboratory animals. Failure to use
caution may cause serious injury or illness.
• Avoid prolonged breathing of vapors.
• Keep face away from nozzle and gas
tank/container opening.
• Keep away from eyes and skin.
• Never siphon by mouth.
Important: Do not use kerosene or gasoline
instead of diesel fuel. Failure to observe this
caution will damage the engine.
Biodiesel Ready
This machine can also use a biodiesel blended fuel
of up to B20 (20% biodiesel, 80% petrodiesel). The
petrodiesel portion should be low or ultra low sulfur.
Observe the following precautions:
• The biodiesel portion of the fuel meet specification
CAUTION
ASTM D6751 or EN14214.
Fuel tank vent is located inside the roll
bar tube. Removing or modifying the roll
bar could result in fuel leakage and violate
emissions regulations.
• Do Not remove roll bar.
• Do Not weld, drill, or modify roll bar in any
way.
• The blended fuel composition should meet ASTM
D975 or EN590.
• Painted surfaces may be damaged by biodiesel
blends.
• Use B5 (biodiesel content of 5%) or lesser blend
in cold weather.
• Monitor seals, hoses, gaskets in contact with fuel
as they may degrade over time.
To help prevent fires:
18
Performing Daily
Maintenance
• Fuel filter plugging may be expected for a time
after converting to biodiesel blends.
• Contact your distributor for more information on
biodiesel.
Before starting the machine each day, perform the
Each Use/Daily procedures listed in Maintenance
(page 37).
Filling the Fuel Tank
1.
Park the machine on a level surface.
2.
Engage the parking brake.
3.
Shut off the engine and remove the key.
4.
Clean around the fuel-tank cap.
5.
Fill the fuel tank to the bottom of the filler neck
(Figure 7).
Breaking in a New Machine
New engines take time to develop full power. Mower
decks and drive systems have higher friction when
new, placing additional load on the engine. Allow
40 to 50 hours of break-in time for new machines to
develop full power and best performance.
Note: Do not fill the fuel tank completely full.
Using the Rollover
Protection System (ROPS)
The empty space in the tank allows the fuel to
expand.
WARNING
To avoid injury or death from rollover, keep
the roll bar in the fully raised, locked position
and use the seat belt.
Ensure that the seat is secured to the
machine.
WARNING
There is no rollover protection when the roll
bar is in the down position.
• Lower the roll bar only when absolutely
necessary.
• Do not wear the seat belt when the roll bar
is in the down position.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance
permits.
• Check carefully for overhead clearances
(i.e., branches, doorways, electrical wires)
before driving under any objects and do
not contact them.
Lowering the Roll Bar
g027726
Figure 7
Important: Lower the roll bar only when
absolutely necessary.
19
1.
To lower the roll bar, apply forward pressure to
the upper part of the roll bar.
2.
Pull both knobs out and rotate them 90 degrees
so they are not engaged (Figure 8).
3.
Lower the roll bar to the down position (Figure 8)
Using the Safety-Interlock
System
WARNING
If the safety-interlock switches are
disconnected or damaged, the machine could
operate unexpectedly, causing personal
injury.
• Do not tamper with the interlock switches.
• Check the operation of the interlock
switches daily and replace any damaged
switches before operating the machine.
g225804
Figure 8
1. Upper part of the roll bar
4. Rotate the knob out 90°
to hold it in the unlatched
position.
2. Knob in the latched
position
5. Knob in the unlatched
position
Understanding the
Safety-Interlock System
The safety-interlock system is designed to prevent the
engine from starting unless:
• The parking brake is engaged.
3. Pull the knob to unlatch.
• The blade-control switch (PTO) is disengaged.
• The motion-control levers are in the NEUTRAL-LOCK
Raising the Roll Bar
position.
Important: Always use the seat belt with the roll
bar in the raised position.
1.
Raise the roll bar to the operating position and
rotate the knobs until they move partially into
the grooves (Figure 9).
The safety-interlock system also is designed to shut
off the engine when the motion-control levers are
moved from the NEUTRAL-LOCK position with the
parking brake engaged or if you rise from the seat
when the PTO is engaged.
2.
Raise the roll bar to the full upright position while
pushing on the upper roll bar so that the pins
snap into position when the holes align with the
pins (Figure 9).
The Horizon Display Monitor has indicators to notify
the user when the interlock component is in the
correct position. When the component is in the correct
position, an indicator displays on the screen.
3.
Push on the roll bar and ensure that both pins
are engaged (Figure 9).
g230650
Figure 10
1. Indicators display when the interlock components are in the
correct position
Testing the Safety-Interlock
System
g008619
Figure 9
1. Engaged
2. Partially engaged—do not
operate the machine with
the ROPS in this position.
Service Interval: Before each use or daily
Test the safety-interlock system before you use the
machine each time. If the safety system does not
20
Unlatching the Seat
operate as described below, have an Authorized
Service Dealer repair the safety system immediately.
1.
Sit on the seat, engage the parking brake, and
move the blade-control switch (PTO) to the ON
position. Try starting the engine; the engine
should not start.
2.
Sit on the seat, engage the parking brake, and
move the blade-control switch (PTO) to the OFF
position. Move either motion-control lever out
of the NEUTRAL-LOCK position. Try starting the
engine; the engine should not start. Repeat for
the other control lever.
3.
Sit on the seat, engage the parking brake,
move the blade-control switch (PTO) to the OFF
position, and move the motion-control levers
to the NEUTRAL-LOCK position. Now start the
engine. While the engine is running, disengage
the parking brake, engage the blade-control
switch (PTO), and rise slightly from the seat; the
engine should shut off.
4.
5.
To unlatch the seat, push the seat latch forward
(Figure 12).
g008956
Figure 12
1. Seat latch
2. Seat
Changing the Seat
Suspension
Sit on the seat, engage the parking brake,
move the blade-control switch (PTO) to the OFF
position, and move the motion-control levers
to the NEUTRAL-LOCK position. Now start the
engine. While the engine is running, center
either motion control and move (forward or
reverse); the engine should shut off. Repeat for
other motion control.
The seat is adjustable to provide a smooth and
comfortable ride. Position the seat where you are
most comfortable.
To adjust it, turn the knob in front either direction to
provide the best comfort (Figure 13).
Sit on the seat, disengage the parking brake,
move the blade-control switch (PTO) to the OFF
position, and move the motion-control levers
to the NEUTRAL-LOCK position. Try starting the
engine; the engine should not start.
Positioning the Seat
The seat can move forward and backward. Position
the seat where you have the best control of the
machine and are most comfortable (Figure 11).
g019768
Figure 13
1. Seat-suspension knob
g019754
Figure 11
21
During Operation
• Be sure all drives are in neutral and parking brake
During Operation Safety
•
General Safety
•
The operator must use their full attention when
operating the machine. Do Not engage in any activity
that causes distractions; otherwise, injury or property
damage may occur.
•
WARNING
Operating engine parts, especially the muffler,
become extremely hot. Severe burns can
occur on contact and debris, such as leaves,
grass, brush, etc. can catch fire.
• Allow engine parts, especially the muffler,
to cool before touching.
• Remove accumulated debris from muffler
and engine area.
•
WARNING
Hands, feet, hair, clothing, or accessories
can become entangled in rotating parts.
Contact with the rotating parts can
cause traumatic amputation or severe
lacerations.
– Do Not operate the machine without
guards, shields, and safety devices in
place and working properly.
– Keep hands, feet, hair, jewelry, or
clothing away from rotating parts.
WARNING
Engine exhaust contains carbon monoxide,
which is an odorless deadly poison that can
kill you.
Do Not run engine indoors or in a small
confined area where dangerous carbon
monoxide fumes can collect.
• Never raise the deck with blades running.
• Be aware of the mower discharge path and direct
• The owner/user can prevent and is responsible
•
•
•
•
•
•
is engaged before starting engine. Use seat belts
with the roll bar in the raised and locked position.
Start the engine carefully according to instructions
with feet well away from the blades.
Never operate the mower with damaged guards,
shields, or covers. Always have safety shields,
guards, switches and other devices in place and in
proper working condition.
Keep clear of the discharge opening at all times.
Never mow with the discharge door raised,
removed or altered unless there is a grass
collection system or mulch kit in place and working
properly.
Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running.
for accidents or injuries occurring to himself or
herself, other people or property.
This mower was designed for one operator only.
Do not carry passengers and keep all others away
from machine during operation.
Do Not operate the machine under the influence
of alcohol or drugs.
Operate only in daylight or good artificial light.
Lightning can cause severe injury or death. If
lightning is seen or thunder is heard in the area,
Do Not operate the machine; seek shelter.
Use extra care while operating with accessories or
attachments, such as grass collection systems.
These can change the stability of the machine
and cause a loss of control. Follow directions for
counter weights if required.
Keep away from holes, ruts, bumps, rocks, and
other hidden hazards. Use care when approaching
blind corners, shrubs, trees, tall grass or other
objects that may hide obstacles or obscure vision.
Uneven terrain could overturn the machine or
cause the operator to lose their balance or footing.
•
•
•
22
discharge away from others. Avoid discharging
material against a wall or obstruction as the
material may ricochet back toward the operator.
Stop the blades, slow down, and use caution when
crossing surfaces other than grass and when
transporting the mower to and from the area to be
mowed.
Be alert, slow down and use caution when
making turns. Look behind and to the side before
changing directions. Do Not mow in reverse
unless absolutely necessary.
Do Not change the engine governor setting or
overspeed the engine.
Park the machine on level ground. Shut off the
engine and wait for all moving parts to stop.
– Before checking, cleaning or working on the
mower.
– After striking a foreign object or abnormal
vibration occurs (inspect the mower for
damage and make repairs before restarting
and operating the mower).
– Before clearing blockages.
•
•
distance (twice the width of the machine) between
the machine and any hazard. Use a walk behind
machine or a hand trimmer to mow the grass in
these areas.
– Whenever you leave the mower. Do Not leave
a running machine unattended.
Stop engine, wait for all moving parts to stop:
– Before refueling.
– Before dumping the grass catcher.
– Before making height adjustments.
Tragic accidents can occur if the operator is not
alert to the presence of children. Children are
often attracted to the machine and the mowing
activity. Never assume that children will remain
where you last saw them.
– Keep children out of the mowing area and
under the watchful care of another responsible
adult, not the operator.
– Be alert and turn the machine off if children
enter the area.
– Before and while backing or changing direction,
look behind, down, and side-to-side for small
children.
– Never allow children to operate the machine.
– Do Not carry children, even with the blades
shut off. Children could fall off and be seriously
injured or interfere with the safe operation of
the machine. Children that have been given
rides in the past could suddenly appear in the
working area for another ride and be run over
or backed over by the machine.
g221745
Figure 14
1. Safe Zone-Use the mower here on slopes less than 15
degrees
2. Danger Zone-Use a walk-behind mower and/or hand
trimmer on slopes greater than 15 degrees
3. Water
4. W=width of the machine
5. Keep a safe distance (twice the width of the machine)
between the machine and any hazard.
Slope Safety
• Avoid starting, stopping or turning the machine on
• Slopes are a major factor related to loss of control
•
slopes. Avoid making sudden changes in speed or
direction; turn slowly and gradually.
and rollover accidents, which can result in severe
injury or death. The operator is responsible for
safe slope operation. Operating the machine on
any slope requires extra caution. Before using the
machine on a slope, the operator must:
– Review and understand the slope instructions
in the manual and on the machine.
– Use an angle indicator to determine the
approximate slope angle of the area.
– Never operate on slopes greater than 15
degrees.
– Evaluate the site conditions of the day to
determine if the slope is safe for machine
operation. Use common sense and good
judgment when performing this evaluation.
Changes in the terrain, such as moisture, can
quickly affect the operation of the machine on
a slope.
Identify hazards at the base of the slope. Do
Not operate the machine near drop offs, ditches,
embankments, water or other hazards. The
machine could suddenly roll over if a wheel goes
over the edge or the edge collapses. Keep a safe
• Do Not operate a machine under any conditions
where traction, steering or stability is in question.
Be aware that operating the machine on wet
grass, across slopes or downhill may cause the
machine to lose traction. Loss of traction to the
drive wheels may result in sliding and a loss of
braking and steering. The machine can slide even
if the drive wheels are stopped.
• Remove or mark obstacles such as ditches, holes,
ruts, bumps, rocks or other hidden hazards. Tall
grass can hide obstacles. Uneven terrain could
overturn the machine.
• Use extra care while operating with accessories or
attachments, such as grass collection systems.
These can change the stability of the machine
and cause a loss of control. Follow directions for
counter weights.
• If possible, keep the deck lowered to the ground
while operating on slopes. Raising the deck while
operating on slopes can cause the machine to
become unstable.
23
Rollover Protection System
(ROPS) Safety
Operating the Parking
Brake
A Rollover Protection System (roll bar) is installed on
the machine.
Always engage the parking brake when you stop the
machine or leave it unattended.
WARNING
Engaging the Parking Brake
There is no rollover protection when the roll
bar is down. Wheels dropping over edges,
ditches, steep banks, or water can cause
rollovers, which may result in serious injury,
death or drowning.
Park the machine on a level surface.
• Do Not remove the ROPS.
• Keep the roll bar in the raised and locked
position and use seat belt.
• Lower the roll bar only when absolutely
necessary.
• Do Not wear seat belt when the roll bar is
down.
• Drive slowly and carefully.
g227611
• Raise the roll bar as soon as clearance
permits.
Figure 15
• Be certain that the seat belt can be released
Disengaging the Parking Brake
quickly in the event of an emergency.
• Check carefully for overhead clearances (i.e.
branches, doorways, and electrical wires) before
driving under any objects and Do Not contact
them.
• In the event of a rollover, take the unit to an
Authorized Service Dealer to have the ROPS
inspected.
• Replace a damaged ROPS. Do Not repair or
revise.
• Any accessories, alterations, or attachments
added to the ROPS must be approved by Toro.
g227610
Figure 16
24
Operating the Mower
Starting the Engine
Blade-Control Switch (PTO) Important: Do not engage starter for more than 5
seconds at a time. If the engine fails to start, wait
15 seconds between attempts. Failure to follow
these instructions can burn out the starter motor.
The blade-control switch (PTO) starts and stops the
mower blades and any powered attachments.
Note: You may need multiple attempts to start the
Engaging the Blade-Control
Switch (PTO)
engine the first time after adding fuel to an empty fuel
system.
Note: Engaging the blade-control switch (PTO) with
the throttle position at half or less causes excessive
wear to the drive belts.
g008945
Figure 17
Disengaging the Blade-Control
Switch (PTO)
g009174
Figure 18
g230704
Figure 19
25
Shutting Off the Engine
Using the Motion-Control
Levers
CAUTION
Children or bystanders may be injured if they
move or attempt to operate the machine while
it is unattended.
Always remove the key and engage the
parking brake when leaving the machine
unattended.
g004532
Figure 21
1. Motion-control
lever—NEUTRAL-LOCK
position
4. Backward
2. Center, unlocked position
5. Front of machine
3. Forward
g230715
Figure 20
26
Driving the Machine
The drive wheels turn independently, powered by
hydraulic motors on each axle. You can turn 1 side
in reverse while you turn the other forward, causing
the machine to spin rather than turn. This greatly
improves the machine maneuverability but may
require some time for you to adapt to how it moves.
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place
the throttle control in the FAST position for best
performance. Always operate in the full throttle
position when mowing.
WARNING
The machine can spin very rapidly. You
may lose control of the machine and cause
personal injury or damage to the machine.
• Use caution when making turns.
• Slow the machine down before making
sharp turns.
g008952
Figure 22
Driving Forward
Driving Backward
Note: The engine shuts off when you move the
traction-control with the parking brake engaged.
To stop the machine, pull the motion-control levers
to the NEUTRAL position.
1.
Disengage the parking brake; refer to
Disengaging the Parking Brake (page 24).
2.
Move the levers to the center, unlocked position.
3.
To go forward, slowly push the motion-control
levers forward (Figure 22).
1.
Move the levers to the center, unlocked position.
2.
To go backward, slowly pull the motion-control
levers rearward (Figure 23).
g008953
Figure 23
27
Using the Side Discharge
Adjusting the Height of Cut
Machines with Side Discharge
Only
Adjust the height of cut from 25 to 140 mm (1 to 5-1/2
inches) in 6 mm (1/4 inch) increments by moving the
clevis pin into different hole locations.
The mower has a hinged grass deflector that
disperses clippings to the side and down toward the
turf.
DANGER
Without a grass deflector, discharge cover, or
a complete grass-catcher assembly mounted
in place, you and others are exposed to blade
contact and thrown debris. Contact with
rotating mower blade(s) and thrown debris
will cause injury or death.
1.
With the engine running, push the deck-lift
switch rearward until the mower deck is fully
raised, and release the switch immediately.
2.
Rotate the height-of-cut pin until the roll pin
in it lines up with the slots in the holes in the
height-of-cut bracket and remove it (Figure 24).
3.
Insert the height-of-cut pin into the hole
corresponding to the desired cutting height
(Figure 24).
Refer to the decal on the side of the deck-lift
plate for the heights of cut (Figure 24).
• Never remove the grass deflector from the
mower deck because the grass deflector
routes material down toward the turf. If the
grass deflector is ever damaged, replace it
immediately.
4.
Using the deck-lift switch, move the deck height
out of the transport position (or 5-1/2 inches (140
mm) cutting height) and down to the selected
height.
• Never put your hands or feet under the
mower deck.
• Never try to clear the discharge area
or mower blades unless you move the
blade-control switch (PTO) to the OFF
position, rotate the key switch to the OFF
position, and remove the key from the key
switch.
• Make sure that the grass deflector is in the
down position.
g227689
Figure 24
1. Height-of-cut bracket
28
2. Height-of-cut pin
Adjusting the Anti-Scalp
Rollers
For maximum deck flotation, install the rollers 1 hole
position lower. Rollers should maintain a 6 mm (1/4
inch) clearance to the ground. Do not adjust the
rollers to support the deck.
1.
Park the machine on a level surface.
2.
Disengage the blade-control switch (PTO), move
the motion-control levers to the NEUTRAL-LOCK
position, and engage the parking brake.
3.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
4.
Adjust the anti-scalp rollers as shown in Figure
25, Figure 26, Figure 27, and Figure 28.
g227782
Figure 26
Side Discharge Machines
1. Bolt
4. Spacer
2. Bushing
5. Flange nut
3. Anti-scalp roller
g227785
Figure 25
1. Flange nut
3. Bushing
2. Anti-scalp roller
4. Bolt
g227784
Figure 27
Side Discharge Machines
1. Bolt
4. Spacer
2. Bushing
5. Flange nut
3. Anti-scalp roller
29
Adjusting the Skids
For Models with Rear Discharge
Mount the skids in the lower position when operating
at heights of cut greater than 51 mm (2 inches) and
in a higher position when operating at heights of cut
lower than 51 mm (2 inches).
Adjust the skids as shown in Figure 29.
g227783
Figure 28
Rear Discharge Machines
1. Bolt
3. Anti-scalp roller
2. Bushing
4. Flange nut
5.
6.
For side discharge machines, torque the
flange nut to 68 to 75 N∙m (50 to 55 ft-lb).
g035646
Figure 29
For rear discharge machines, torque the
flange nut to 41 to 47 N∙m (30 to 35 ft-lb).
Adjusting the Flow Baffle
Knob
For Machines with Side Discharge
This procedure applies only to machines with the
flow baffle knob. Certain models have nuts and bolts
instead of the flow baffle knob that you can adjust the
same way.
You can adjust the mower discharge flow for different
types of mowing conditions. Position the knob and
baffle to give the best quality of cut.
30
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Loosen the knob.
4.
Slide the knob to the desired position.
5.
Tighten the knob.
Positioning the Flow Baffle
Position B
For Machines with Side Discharge
Use this position when bagging. Always align it with
the blower opening.
The following figures are recommendations only.
Adjustments vary by grass type, moisture content,
and the height of the grass.
Note: If the engine power draws down and the
mower ground speed is the same, open the baffle.
Position A
This is the fully-rear position. The suggested use for
this position is as follows:
• Short, light grass mowing conditions
• Dry conditions
• Smaller grass clippings
• Propels grass clippings farther away from the
mower
g295811
Figure 31
Position C
This is the fully-forward position. The suggested use
for this position is as follows:
• Tall, dense grass mowing conditions
• Wet conditions
• Lowers the engine-power consumption
• Allows increased ground speed in heavy conditions
g295810
Figure 30
31
g295812
Figure 32
Operating with the Overheat
Sensor
The PTO disengages, an alarm sounds, and a
bar graph displays the engine temperature when it
reaches an overheat condition. The PTO does not
engage until the engine has cooled and you manually
shut off the PTO and engage it.
Note: If the engine-coolant level is below the indicator
line on the overflow bottle when the engine is cold, the
coolant temperature gauge may not register correctly
during operation and/or the audible alarm may not
sound if the engine overheats.
32
Operating Tips
drop onto your lawn. To avoid this, move onto a
previously cut area with the blades engaged or you
can disengage the mower deck while moving forward.
Using the Fast Throttle Setting
For best mowing and maximum air circulation, operate
the engine at the FAST position. Air is required to
thoroughly cut grass clippings, so do not set the
height-of-cut so low as to totally surround the mower
deck in uncut grass. Always try to have 1 side of the
mower deck free from uncut grass, which allows air
to be drawn into the mower deck.
Keeping the Underside of the
Mower Deck Clean
Clean clippings and dirt from the underside of the
mower deck after each use. If grass and dirt build up
inside the mower deck, cutting quality will eventually
become unsatisfactory.
Cutting a Lawn for the First Time
Maintaining the Blade(s)
Cut grass slightly longer than normal to ensure that
the cutting height of the mower deck does not scalp
any uneven ground. However, the cutting height
used in the past is generally the best one to use.
When cutting grass longer than 15 cm (6 inches) tall,
you may want to cut the lawn twice to ensure an
acceptable quality of cut.
Maintain a sharp blade throughout the cutting season
because a sharp blade cuts cleanly without tearing or
shredding the grass blades. Tearing and shredding
turns grass brown at the edges, which slows growth
and increases the chance of disease. Check the
mower blades after each use for sharpness, and
for any wear or damage. File down any nicks and
sharpen the blades as necessary. If a blade is
damaged or worn, replace it immediately with a
genuine Toro replacement blade.
Cutting a Third of the Grass Blade
It is best to cut only about a third of the grass blade.
Cutting more than that is not recommended unless
grass is sparse, or it is late fall when grass grows
more slowly.
Alternating the Mowing Direction
Alternate the mowing direction to keep the grass
standing straight. This also helps disperse clippings,
which enhances decomposition and fertilization.
Mowing at Correct Intervals
Grass grows at different rates at different times of
the year. To maintain the same cutting height, mow
more often in early spring. As the grass growth rate
slows in mid summer, mow less frequently. If you
cannot mow for an extended period, first mow at a
high cutting height, then mow again 2 days later at a
lower height setting.
Using a Slower Cutting Speed
To improve cut quality, use a slower ground speed
in certain conditions.
Avoiding Cutting Too Low
When mowing uneven turf, raise the cutting height
to avoid scalping the turf.
Stopping the Machine
If you must stop the forward motion of the machine
while mowing, a clump of grass clippings may
33
After Operation
After Operation Safety
General Safety
• Park machine on level ground, disengage drives,
set parking brake, stop engine, and remove
key. Wait for all movement to stop and allow
the machine to cool before adjusting, cleaning,
repairing, or storing. Never allow untrained
personnel to service machine.
• Clean the machine as stated in the Maintenance
section. Keep engine and engine area free from
accumulation of grass, leaves, excessive grease
or oil, and other debris which can accumulate
in these areas. These materials can become
combustible and may result in a fire.
g004644
Figure 33
1. Right bypass valve
• Frequently check for worn or deteriorating
2. Left bypass valve
components that could create a hazard. Tighten
loose hardware.
Transporting
Using the Drive-Wheel
Release Valves
Transporting the Machine
Use a heavy-duty trailer or truck to transport the
machine. Ensure that the trailer or truck has all
necessary lighting and marking as required by law.
Thoroughly read all of the safety instructions. Knowing
this information could help you, your family, pets, or
bystanders avoid injury.
Use the drive-wheel release valves to release the
hydrostatic drive system, which allows you to push the
machine without the running the engine.
Rotate each bypass valve counterclockwise 1 turn to
release; rotate each bypass valve clockwise to reset
system (Figure 33).
To transport the machine:
Important: Do not overtighten. Do not tow the
• Lock the brake and block the wheels.
machine.
• Securely fasten the machine to the trailer or
truck with straps, chains, cable, or ropes. Only
use the designated tie-down locations on the
mower (Figure 34). Use these locations even
when transporting the mower with an attached
accessory. Using non-designated locations may
cause damage to the mower and/or attachment.
34
WARNING
Loading a machine onto a trailer or truck
increases the possibility of tip-over and could
cause serious injury or death.
• Use extreme caution when operating a
machine on a ramp.
• Ensure that the ROPS is in the up position
and use the seat belt when loading or
unloading the machine. Ensure that the
ROPS will clear the top of an enclosed
trailer.
g225819
Figure 34
1. Tie-down location
• Secure a trailer to the towing vehicle with safety
chains.
• Use only a full-width ramp; do not use
individual ramps for each side of the
machine.
WARNING
Driving on the street or roadway without
turn signals, lights, reflective markings,
or a slow moving vehicle emblem is
dangerous and can lead to accidents
causing personal injury.
• Do not exceed a 15-degree angle between
the ramp and the ground or between the
ramp and the trailer or truck.
• Ensure the length of ramp is at least four
times (4X) as long as the height of the
trailer or truck bed to the ground. This will
ensure that ramp angle does not exceed 15
degrees on flat ground.
Do not drive machine on a public street or
roadway.
Loading the Machine
• Back up ramps and drive forward down
ramps.
Use extreme caution when loading or unloading
machines onto a trailer or a truck. Use a full-width
ramp that is wider than the machine for this procedure.
Back up ramps and drive forward down ramps (Figure
35).
• Avoid sudden acceleration or deceleration
while driving the machine on a ramp as
this could cause a loss of control or a
tip-over situation.
g028043
Figure 35
1. Back up ramps
2. Drive forward down ramps
Important: Do not use narrow individual ramps
for each side of the machine.
Ensure the ramp is long enough so that the angle with
the ground does not exceed 15 degrees (Figure 36).
On flat ground, this requires a ramp to be at least four
times (4X) as long as the height of the trailer or truck
bed to the ground. A steeper angle may cause mower
components to get caught as the unit moves from the
ramp to the trailer or truck. Steeper angles may also
cause the machine to tip or lose control. If loading on
or near a slope, position the trailer or truck so that it is
on the down side of the slope and the ramp extends
up the slope. This will minimize the ramp angle.
35
and loss of control. Reduce the towed weight and
slow down.
• Stopping distance increases with the weight of the
towed load. Travel slowly and allow extra distance
to stop.
• Make wide turns to keep the attachment clear of
the machine.
g027996
Figure 36
1. Full-width ramp in stowed
position
4. Ramp is at least four times
(4X) as long as the height
of the trailer or truck bed
to the ground
2. Side view of full-width
ramp in loading position
5. H= height of the trailer or
truck bed to the ground
3. Not greater than
15 degrees
6. Trailer
Towing Safety
• Do not attach towed equipment except at the hitch
point.
• Follow the attachment manufacturer's
recommendation for weight limits for towed
equipment and towing on slopes. Towed
weight must not exceed the weight of the
machine, operator, and ballast; otherwise
hydrostatic transmission failure may occur. Use
counterweights or wheel weights as described in
the attachment manufacturer's manual.
• Never allow children or others in or on towed
equipment.
• On slopes, the weight of the towed equipment may
cause loss of traction, increased risk of rollover,
36
Maintenance
WARNING
Hydraulic fluid escaping under pressure
can penetrate skin and cause injury. Fluid
accidentally injected into the skin must be
surgically removed within a few hours by
a doctor familiar with this form of injury or
gangrene may result.
Maintenance Safety
WARNING
While maintenance or adjustments are being
made, someone could start the engine.
Accidental starting of the engine could
seriously injure you or other bystanders.
– If equipped, make sure all hydraulic
fluid hoses and lines are in good
condition and all hydraulic connections
and fittings are tight before applying
pressure to hydraulic system.
Remove the key from the ignition switch and
engage parking brake before you do any
maintenance.
– Keep body and hands away from
pinhole leaks or nozzles that eject high
pressure hydraulic fluid.
WARNING
– Use cardboard or paper, not your hands,
to find hydraulic leaks.
The engine can become very hot. Touching a
hot engine can cause severe burns.
– Safely relieve all pressure in the
hydraulic system by placing the motion
control levers in neutral and shutting off
the engine before performing any work
on the hydraulic system.
Allow the engine to cool completely before
service or making repairs around the engine
area.
• Park machine on level ground, disengage drives,
set parking brake, stop engine, and remove
key. Wait for all movement to stop and allow
the machine to cool before adjusting, cleaning
or repairing. Never allow untrained personnel to
service machine.
WARNING
Fuel system components are under high
pressure. The use of improper components
can result in system failure, fuel leakage
and possible explosion.
• Disconnect battery before making any repairs.
Disconnect the negative terminal first and the
positive last. Reconnect positive first and negative
last.
Use only approved fuel lines and fuel filters
for high pressure systems.
• Keep the machine, guards, shields and all
safety devices in place and in safe working
condition. Frequently check for worn or
deteriorating components and replace them with
the manufacturer’s recommended parts when
necessary.
• Use care when checking blades. Wrap the
blade(s) or wear gloves, and use caution when
servicing them. Only replace damaged blades.
Never straighten or weld them.
• Use jack stands to support the machine and/or
components when required.
WARNING
Removal or modification of original
equipment, parts and/or accessories
may alter the warranty, controllability,
and safety of the machine. Unauthorized
modifications to the original equipment or
failure to use original Toro parts could lead
to serious injury or death. Unauthorized
changes to the machine, engine, fuel or
venting system, may violate applicable
safety standards such as: ANSI, OSHA and
NFPA and/or government regulations such
as EPA and CARB.
CAUTION
Raising the machine for service or
maintenance relying solely on mechanical
or hydraulic jacks could be dangerous.
The mechanical or hydraulic jacks may not
be enough support or may malfunction
allowing the machine to fall, which could
cause injury.
Do not rely solely on mechanical or
hydraulic jacks for support. Use adequate
jack stands or equivalent support.
37
• Carefully release pressure from components with
WARNING
stored energy.
Contact with moving parts or hot surfaces
may cause personal injury.
• Keep hands and feet away from moving parts.
If possible, Do Not make adjustments with the
engine running. If the maintenance or adjustment
procedure require the engine to be running and
components moving, use extreme caution.
Keep your fingers, hands, and clothing
clear of rotating components and hot
surfaces.
• Check all bolts frequently to maintain proper
tightness.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 100 hours
• Check the wheel lug nuts.
• Adjust the parking brake.
After the first 200 hours
• Change the engine oil and filter.
• Change the deck gearbox oil.
• Change the hydraulic fluid and filter.
Before each use or daily
•
•
•
•
•
•
•
•
Check the safety-interlock system.
Check the engine-oil level.
Check the seat belt.
Check the engine-coolant level.
Check the hydraulic-fluid level.
Inspect the blades.
Clean the engine and exhaust system area.
Clean the grass and debris build-up from the machine and mower deck.
Every 50 hours
•
•
•
•
•
•
Grease the drive U-joints and splined slip joint.
Drain the fuel filter/water separator.
Check the tire pressure
Check the gearbox-oil level.
Clean the engine-cooling system (more often in dirty and dusty conditions).
Inspect the belts for cracks and wear.
Every 100 hours
• Check the alternator-belt tension.
Every 200 hours
• Change the engine oil and filter if not using Toro Premium Engine Oil, but any oil
meeting API classification CJ-4 or higher or as stated in Engine-Oil Specifications.
•
•
•
•
Every 400 hours
•
•
•
•
•
Grease the deck-idler pivots.
Grease the caster pivots (more often in dirty or dusty conditions).
Service the air cleaner (More frequently in extremely dusty or dirty conditions).
Change the engine oil and filter if using Toro Premium Engine Oil (API classification
CK-4 or higher) (more often in dirty or dusty conditions).
Replace the fuel-filter canister for the water separator (more often in dirty and
dusty conditions).
Check the fuel lines and connections.
Change the deck gearbox oil.
Adjust the parking brake.
Change the hydraulic fluid and filter if using Mobil® 424 hydraulic fluid.
Every 500 hours
• Adjust the caster-pivot bearing.
Every 800 hours
• Inspect the engine-valve clearance.
• Change the hydraulic fluid and filter if using Toro Premium Transmission/Hydraulic
Tractor Fluid.
Every 2,000 hours
• Change the engine coolant.
38
Maintenance Service
Interval
Monthly
Yearly
Maintenance Procedure
• Check the battery charge.
•
•
•
•
Grease the deck drive PTO.
Repack the caster-wheel bearings (more often in dirty or dusty conditions).
Greasing the caster-wheel hubs.
If you operate the machine less than 200 hours, change the engine oil and filter.
Important: Refer to your engine owner's manual for additional maintenance procedures.
CAUTION
If you leave the key in the switch, someone could accidently start the engine and seriously
injure you or other bystanders.
Shut off the engine and remove the key from the switch before you perform any maintenance.
39
Lubrication
Greasing the Machine
Service Interval: Every 400 hours/Yearly (whichever
comes first)—Grease the deck-idler
pivots.
Yearly—Grease the deck drive PTO.
Grease more frequently when operating conditions
are extremely dusty or sandy.
Grease Type: No. 2 lithium or molybdenum grease
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Clean the grease fittings with a rag.
Lubricating the Drive
U-Joints and Splined Slip
Joint
Note: Make sure that you scrape any paint off
Service Interval: Every 50 hours—Grease the drive
U-joints and splined slip joint.
the front of the fitting(s).
Note: For easier access to the drive U-joints and
4.
Connect a grease gun to the fitting.
5.
Pump grease into the fittings until grease begins
to ooze out of the bearings.
splined slip joint, remove the floor pan and fully lower
the mower deck.
6.
Wipe up any excess grease.
Refer to the following chart for fitting locations and
lubrication schedule.
Lubrication Chart
Fitting
Locations
Initial Pumps
Number of
Places
Service
Interval
1. Deck-drive
PTO
1
3
Every 50
hours
2. Deck-idler
pivots
1
1
Every 400
hours or
yearly
3.
Caster-wheel
bearings
0
2
Yearly
4. Caster
pivots
0
2
Every 400
hours or
yearly
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Clean the grease fittings with a rag.
4.
Connect a grease gun to the fitting.
5.
Pump grease into the fittings until grease begins
to ooze out of the bearings.
6.
Wipe up any excess grease.
g250852
Figure 37
40
Greasing the Caster Pivots
6.
Service Interval: Every 400 hours/Yearly (whichever
comes first) (more often in dirty or
dusty conditions).
Yearly—Repack the caster-wheel bearings
(more often in dirty or dusty conditions).
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Remove the dust cap and adjust the caster
pivots and keep the dust cap off until greasing is
done; refer to Adjusting the Caster-Pivot Bearing
(page 49).
4.
Remove the hex plug.
5.
Thread a grease fitting into the hole.
6.
Pump grease into the fitting until it oozes out
around the top bearing.
7.
Remove the grease fitting from the hole. Install
the hex plug and cap.
Note: Thread-locking compound has been
applied to lock the spacer nuts to the axle.
Service Interval: Yearly
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Raise the mower for access.
4.
Remove the caster wheel from the caster forks.
5.
Remove the seal guards from the wheel hub.
7.
Remove the axle (with the other spacer nut still
assembled to it) from the wheel assembly.
8.
Pry out seals and inspect bearings for wear or
damage and replace if necessary.
9.
Pack the bearings with a general-purpose
grease.
10.
Insert 1 bearing and 1 new seal into the wheel.
11.
If the axle assembly is missing both spacer nuts,
apply a thread-locking compound to 1 spacer
nut and thread it onto the axle with the wrench
flats facing outward.
Note: Do not thread the spacer nut all of
the way onto the end of the axle. Leave
approximately 3 mm (1/8 inch) from the outer
surface of the spacer nut to the end of the axle
inside the nut.
Greasing the Caster-Wheel
Hubs
1.
Remove a spacer nut from the axle assembly in
the caster wheel.
12.
Insert the assembled nut and axle into the wheel
on the side with the new seal and bearing.
13.
With the open end of the wheel facing up, fill
the area inside the wheel around the axle full of
general-purpose grease.
14.
Insert the second bearing and new seal into the
wheel.
15.
Apply a thread-locking compound to the second
spacer nut, and thread it onto the axle with the
wrench flats facing outward.
16.
Torque the nut to 8 to 9 N∙m (75 to 80 in-lb),
loosen the nut, then torque it to 2 to 3 N∙m (20
to 25 in-lb).
Note: Make sure that the axle does not extend
beyond either nut.
17.
Install the seal guards over the wheel hub, and
insert the wheel into the caster fork.
18.
Install the caster bolt and tighten the nut fully.
Important: To prevent seal and bearing damage,
check the bearing adjustment often. Spin the
caster tire. The tire should not spin freely (more
than 1 or 2 revolutions) or have any side play. If
the wheel spins freely, adjust the torque on the
spacer nut until there is a slight amount of drag.
Apply another layer of thread-locking compound.
g006115
Figure 38
1. Seal guard
2. Spacer nut with wrench
flats
41
Engine Maintenance
Servicing the Air Cleaner
Note: If the foam gasket in the cover is damaged,
Engine Safety
replace it.
• Shut off the engine before checking the oil or
Important: Avoid using high-pressure air, which
could force dirt through the filter into the intake
tract.
adding oil to the crankcase.
Keep your hands, feet, face, clothing, and other
body parts away the muffler and other hot surfaces.
•
Important: Do not clean the used filter to avoid
damaging the filter media.
Servicing the Air Cleaner
Important: Do not use a damaged filter.
Service Interval: Every 400 hours
Important: Do not apply pressure to the flexible
center of the filter.
Checking the Air Cleaner
1.
2.
3.
4.
5.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
Check the air-cleaner body for damage, which
could possibly cause an air leak.
Replace a damaged air-cleaner body.
Check the air-intake system for leaks, damage,
or loose hose clamps.
Service the air-cleaner filter when the air-cleaner
indicator shows red (Figure 39).
Important: Do not over-service the air filter.
g004501
Figure 39
1.
2.
3.
4.
6.
Air-cleaner cover
Gasket
Filter
Air-cleaner body
5. Air-cleaner indicator
6. Air-cleaner latch
7. Rubber outlet valve
g031807
Figure 40
Ensure that the cover seats correctly and seals
with the air-cleaner body.
42
Servicing the Engine Oil
3.
Open the hood.
Service Interval: Before each use or daily
After the first 200 hours—Change the engine
oil and filter.
Every 200 hours—Change the engine oil and
filter if not using Toro Premium Engine Oil, but
any oil meeting API classification CJ-4 or higher
or as stated in Engine-Oil Specifications.
Every 400 hours—Change the engine oil and
filter if using Toro Premium Engine Oil (API
classification CK-4 or higher) (more often in
dirty or dusty conditions).
Yearly—If you operate the machine less than
200 hours, change the engine oil and filter.
4.
Check the engine-oil level as shown in Figure
41.
Engine-Oil Specifications
The engine ships with oil in the crankcase; however,
check the oil level before and after you first start
the engine. Check the oil level before operating the
machine each day or each time you use the machine.
Crankcase capacity for Models 74028 and 74029:
4.7 L (5 US qt) with the filter
g029301
Crankcase capacity for Models 74060, 74064,
74072, and 74074: 6.6 L (7 US qt) with the filter
Figure 41
Preferred engine oil: Toro Premium Engine Oil
If using an alternate oil, use high-quality, low-ash
engine oil that meets or exceeds the following
specifications:
• API service category CJ-4 or higher
• ACEA service category E6
• JASO service category DH-2
Important: Using engine oil other than API
classification CJ-4 or higher, ACEA E6, or JASO
DH-2 may cause the diesel particulate filter to plug
or cause engine damage.
Use the following engine oil viscosity grade:
• SAE 10W-30 or 5W-30 (all temperatures)
• SAE 15W-40 (above 0° F)
Note: Toro Premium Engine oil is available from
your distributor. See the Parts Catalog or contact an
authorized Toro distributor for part numbers.
Checking the Engine-Oil Level
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
43
Changing the Engine Oil and Filter
If possible, run the engine just before changing the
oil because warm oil flows better and carries more
contaminants than cold oil.
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Open the hood.
4.
Change the engine oil as shown in Figure 42.
g027477
Figure 43
g031623
Figure 42
6.
5.
Replace the engine-oil filter as shown in Figure
43.
Fill the crankcase with oil; refer to Engine-Oil
Specifications (page 43).
Inspecting the Engine-Valve
Clearance
Service Interval: Every 800 hours
Inspect the engine-valve clearance. Refer to the
engine owner’s manual.
44
Replacing the Water
Separator
Fuel System
Maintenance
Service Interval: Every 400 hours—Replace the
fuel-filter canister for the water
separator (more often in dirty and
dusty conditions).
DANGER
In certain conditions, fuel is extremely
flammable and highly explosive. A fire or
explosion from fuel can burn you and others
and can damage property.
Refer to Fuel Safety (page 17) for a complete
list of fuel related precautions.
Draining the Fuel
Filter/Water Separator
Service Interval: Every 50 hours—Drain the fuel
filter/water separator.
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Place a drain pan below the fuel filter/water
separator.
4.
Open the drain plug on the water separator
approximately 1 turn to allow water and other
contaminates to drain (Figure 44).
g031412
Figure 45
Checking the Fuel Lines
and Connections
g231880
Figure 44
1. Fuel filter/water separator
Service Interval: Every 400 hours
5.
Close the drain plug when only diesel fuel
comes out.
Inspect the fuel lines for deterioration, damage,
chaffing, or loose connections.
Important: Water or other contaminants in
fuel can damage the fuel pump and/or other
engine components.
45
Electrical System
Maintenance
WARNING
Incorrect battery cable routing could damage
the machine and cables causing sparks.
Sparks can cause the battery gasses to
explode, resulting in personal injury.
Electrical System Safety
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
• Disconnect the battery before repairing the
machine. Disconnect the negative terminal first
and the positive last. Connect the positive terminal
first and the negative last.
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
• Charge the battery in an open, well-ventilated
area, away from sparks and flames. Unplug the
charger before connecting or disconnecting the
battery. Wear protective clothing and use insulated
tools.
Servicing the Battery
DANGER
Battery electrolyte contains sulfuric acid,
which is fatal if consumed and causes severe
burns.
1.
Disengage the blade-control switch (PTO), move
the motion-control levers to the NEUTRAL-LOCK
position, and engage the parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Unlatch the seat and tilt the seat up.
4.
Remove the battery as shown in Figure 46.
Do not drink electrolyte and avoid contact
with skin, eyes or clothing. Wear safety
glasses to shield your eyes and rubber gloves
to protect your hands.
Removing the Battery
WARNING
Battery terminals or metal tools could short
against metal machine components, causing
sparks. Sparks can cause the battery gasses
to explode, resulting in personal injury.
• When removing or installing the battery,
do not allow the battery terminals to touch
any metal parts of the machine.
• Do not allow metal tools to short between
the battery terminals and metal parts of the
machine.
g032750
Figure 46
46
Installing the Battery
Note: Do not run the machine with the battery
disconnected, electrical damage may occur.
Note: Position the battery in the tray with the terminal
posts opposite from the hydraulic tank.
g000960
Figure 48
1. Positive battery post
3. Red (+) charger lead
2. Negative battery post
4. Black (-) charger lead
Servicing the Fuses
The electrical system is protected by fuses. It requires
no maintenance, however, if a fuse blows check
component/circuit for malfunction or short.
g032751
Figure 47
Charging the Battery
Service Interval: Monthly—Check the battery charge.
1.
Unlatch the engine hood and raise the engine
hood to gain access to the fuse block.
2.
To replace the fuses, pull out on the fuse to
remove it.
3.
Install a new fuse (Figure 49).
WARNING
Charging the battery produces gasses that
can explode.
Never smoke near the battery and keep sparks
and flames away from battery.
Important: Always keep the battery fully charged
(1.265 specific gravity). This is especially
important to prevent battery damage when the
temperature is below 0°C (32°F).
1.
g235614
Figure 49
Make sure that the filler caps are installed in
battery. Charge battery for 10 to 15 minutes at
25 to 30 A or 30 minutes at 10 A.
2.
When the battery is fully charged, unplug
the charger from the electrical outlet, then
disconnect the charger leads from the battery
posts (Figure 48).
3.
Install the battery in the machine and connect
the battery cables, refer to Installing the Battery
(page 47).
47
1. Accessory (15 A)
3. Main (25 A)
2. Chassis (15 A)
4. Power point (15 A)
Drive System
Maintenance
9.
Align the levers in the front-to-rear position by
bringing the levers together to the NEUTRAL
position, and slide them until they are aligned,
then tighten the bolts (Figure 51).
Checking the Seat Belt
Service Interval: Before each use or daily
Inspect the seat belt for wear, cuts, and proper
operation of the retractor and buckle. Replace the
seat belt if it is damaged.
Adjusting the Tracking
1.
2.
3.
4.
5.
6.
7.
8.
Disengage the blade-control switch (PTO).
Drive to an open flat area, move the
motion-control levers to the NEUTRAL-LOCK
position.
Move the throttle midway between the FAST and
SLOW positions.
Move both motion-control levers all the way
forward until they both hit the stops in the T-slot.
Check which way the machine tracks.
Engage the parking brake, shut off the engine,
and remove the key.
Adjust the stop plates as needed.
• If the machine tracks to the right, loosen the
bolts and adjust the left stop plate rearward
on the left T-slot until the machine tracks
straight (Figure 50).
• If the machine tracks to the left, loosen the
bolts and adjust the right stop plate rearward
on the right T-slot until the machine tracks
straight (Figure 50).
Tighten the stop plate (Figure 50).
g009195
Figure 51
10.
If alignment is needed, loosen the 2
motion-control lever mounting bolts on the
misaligned side (Figure 52).
g254283
Figure 52
11.
Move motion-control lever to meet the opposite
side.
12.
Tighten the 2 motion-control lever mounting
bolts (Figure 52).
g254284
Figure 50
1. Control lever
3. Stop plate
2. Bolt
48
Adjusting the Caster-Pivot
Bearing
Checking the Tire Pressure
Service Interval: Every 50 hours/Monthly (whichever
comes first)
Service Interval: Every 500 hours/Yearly (whichever
comes first)
Rear tire air pressure specification: 124 kPa (18
psi).
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Low tire pressure decreases machine side-hill
stability. This could cause a rollover, which
may result in personal injury or death.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Remove the dust cap from the caster and tighten
the locknut (Figure 54).
Do not under-inflate the tires.
4.
Tighten the locknut until the spring washers are
flat, and then back off a 1/4 turn to properly set
the preload on the bearings (Figure 54).
Note: The caster tires are semi-pneumatic tires and
do not require air pressure maintenance.
DANGER
Check the air pressure in the rear tires. Add or remove
air as needed to set the air pressure in the tires to the
tire air pressure specification.
Important: Make sure that the spring
washers are installed correctly as shown in
Figure 54.
Important: Maintain pressure in all tires to
ensure a good quality of cut and proper machine
performance.
Check the air pressure in all the tires before
operating the machine.
5.
Install the dust cap (Figure 54).
g001055
Figure 53
g228558
Figure 54
1. Spring disc washers
Checking the Wheel Lug
Nuts
Service Interval: After the first 100 hours—Check the
wheel lug nuts.
Torque the wheel lug nuts to 115 to 142 N∙m (85 to
105 ft-lb).
49
Changing the Gearbox Oil
Servicing the Gearbox
Service Interval: After the first 200 hours
Checking the Gearbox-Oil Level
Every 400 hours
Service Interval: Every 50 hours
If the oil becomes contaminated, contact your Toro
Distributor because the system must be flushed.
Contaminated oil looks milky or black when compared
to clean oil.
Use SAE 75W-90 synthetic gear lube.
1.
Park the machine on a level surface and engage
the parking brake.
2.
Lower the mower deck to the 25 mm (1 inch)
height of cut.
3.
Disengage the blade-control switch, shut off the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating
position.
4.
Lift the footrest to expose the top of the mower
deck.
5.
Remove the dipstick/fill plug from the top of the
gearbox and ensure that the lubricant is between
the marks on the dipstick (Figure 55).
1.
Park the machine on a level surface and engage
the parking brake.
2.
Lower the mower deck to the 25 mm (1 inch)
height of cut.
3.
Disengage the blade-control switch, shut off the
engine, remove the key, and wait for all moving
parts to stop before leaving the operating
position.
4.
Lift the footrest to expose the top of the mower
deck.
5.
Remove the dipstick/fill plug from the top of the
gearbox and ensure that the lubricant is between
the marks on the dipstick (Figure 55).
6.
Extract the oil through the fill port using a
vacuum device or remove the gearbox from the
deck and pour out the oil into a drain pan.
7.
Install the gearbox (if it was removed to drain).
8.
Add approximately 420 ml (14 fl oz), until the
level is between the marks on the dipstick
Important: Do not overfill the gearbox;
overfilling the gearbox may damage it.
g231764
Figure 55
1. Fill plug/dipstick
6.
If the oil level is low, add enough lubricant until
the level is between the marks on the dipstick.
Important: Do not overfill the gearbox;
overfilling the gearbox may damage it.
50
Cooling System
Maintenance
Cooling System Safety
• Swallowing engine coolant can cause poisoning;
keep out of reach from children and pets.
• Discharge of hot, pressurized coolant or touching
a hot radiator and surrounding parts can cause
severe burns.
– Always allow the engine to cool at least 15
minutes before removing the radiator cap.
g227787
Figure 56
– Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
1. Expansion-tank cap
3. Add line
2. Full line
Checking the
Engine-Coolant Level
5.
If coolant level is low, remove the expansion-tank
cap, and add the specified coolant (Figure 56).
Important: Do not overfill.
Service Interval: Before each use or daily
Coolant specification: 50/50 solution of water and
permanent ethylene-glycol antifreeze
Cooling-system capacity: 7.6 L (8 US qt)
6.
Install the expansion-tank cap.
7.
Close the hood.
Cleaning the Radiator
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
Clean the radiator to prevent the engine from
overheating.
3.
Open the hood.
Note: If the mower deck or engine shuts off due to
4.
Check the level of the coolant in the expansion
tank (Figure 56).
Service Interval: Every 50 hours—Clean the
engine-cooling system (more often
in dirty and dusty conditions).
overheating, check the radiator for excessive buildup
of debris.
Note: The coolant level should be between the
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Rotate the hood forward.
4.
Using compressed air, blow out debris stuck
between the fins of the entire radiator, both from
the top down and bottom up.
5.
If debris remains, it may be necessary to use
water from a low-pressure hose.
marks on the side of the tank.
If the radiator is clean, proceed to step 7.
6.
51
Cover the engine with a piece of cardboard or
a plastic sheet. Squirt water through the fins.
Blow through with low-pressure air from both
directions.
Note: If debris remains, repeat until clean.
9.
7.
Lower the hood.
8.
Start the engine to ensure that the fan functions
properly.
As air purges from the engine block and the
coolant level drops, add additional coolant to the
radiator.
Changing the Engine
Coolant
10.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Rotate the hood forward.
4.
Drain the coolant when the engine is cool.
5.
Remove the radiator cap, place a pan under
the radiator, and remove the drain plug at the
bottom of the radiator.
6.
Remove the coolant hose from the oil cooler and
drain the coolant from the engine block (Figure
57).
g233651
Figure 57
1. Coolant hose
7.
Install the drain plugs and hoses.
8.
Fill radiator with a 50/50 mix of water and
ethylene glycol.
When the radiator is completely full and no
additional coolant can be added, continue
running and install the radiator cap.
Ensure that the cap is completely seated by
pressing down firmly while turning, until the cap
stops. Once the cap is installed, shut off the
engine.
Service Interval: Every 2,000 hours/Every 2 years
(whichever comes first)
1.
Operate engine until the engine thermostat
opens and the coolant is circulating through the
radiator core.
Note: The use of Havoline® Xtended Life
coolant is recommended.
Allow some room (approximately 12.7 mm (1/2
inch)) for expansion. Add 50/50 coolant mix to
the overflow bottle on the left side of the engine
as required to bring the level up to the indicator
line on the bottle.
52
Brake Maintenance
Adjusting the Parking
Brake
Service Interval: After the first 100 hours
Every 400 hours
Check to ensure that parking brake is adjusted
properly. Follow this procedure also whenever you
have removed or replaced a brake component.
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Raise the rear of the machine up and support
the machine with jack stands.
4.
Remove the rear tires from the machine.
5.
Remove any debris from the brake area.
6.
Release the drive wheels; refer to Using the
Drive-Wheel Release Valves (page 34).
1. Front location
5. Spring
7.
Measure the length of the link assembly (Figure
58).
2. Rear location
6. Link assembly
3. 8.3 cm (3-1/4 inches)
7. Length
g228555
Figure 58
4. Gap
Note: If the link assembly is attached in the
front position, the length should be 21.9 cm
(8.63 inches); if it is attached in the rear position,
the length should be 23.2 cm (9.15 inches).
8.
Measure the length of the spring (Figure 58).
Note: The measurement should be 8.3 cm
(3-1/4 inches).
9.
When you achieve the correct spring length,
check to see if there is a visible gap between the
trunion and the shoulder.
10.
Disengage the parking brake and turn the wheel
hub by hand in both directions.
Note: The wheel hub should move freely.
11.
If a gap is needed or the wheel hub does move
freely, do the following:
A.
Disengage the parking brake.
B.
Disconnect and fine-tune the rear linkage
assembly.
• Shorten the link to create a gap.
• Lengthen the link to allow wheel hub
movement.
C.
12.
53
Connect the rear linkage assembly.
Engage the parking brake and check the gap.
13.
Belt Maintenance
Repeat steps 10 through 12 until a visible gap
is achieved and the wheel hub rotates freely.
Repeat this procedure for the other side.
Inspecting the Belts
Note: The brake should fully disengage when
the brake is in the released position.
14.
Rotate the drive wheel release handle to
the operating position; refer to Using the
Drive-Wheel Release Valves (page 34).
15.
Install the rear tires and torque the lug nuts to
115 to 142 N∙m (85 to 105 ft-lb).
16.
Remove the jack stands.
Service Interval: Every 50 hours
Replace the belt if it is worn. The signs of a worn belt
include squealing while the belt is rotating; the blades
slipping while cutting grass; and frayed edges, burn
marks, and cracks on the belt.
Replacing the Mower Belt
Squealing when the belt is rotating, blades slipping
when cutting grass, frayed belt edges, burn marks
and cracks are signs of a worn mower belt. Replace
the belt if any of these conditions are evident.
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Lower the mower to the 76 mm (3 inches) height
of cut.
4.
Remove the belt covers (Figure 59).
g027729
Figure 59
54
5.
Use a ratchet in the square hole in the idler arm
to remove tension on the idler spring (Figure 60
or Figure 61).
6.
Remove the belt from the mower-deck pulley.
7.
Install the new belt around the mower pulleys
(Figure 60 or Figure 61).
g235768
Figure 60
Rear Discharge Machine Shown
g027730
Figure 62
1. Spring
3. Spring-loaded idler pulley
2. Square hole in the idler
arm for the ratchet
4. Mower belt
Checking the
Alternator-Belt Tension
Service Interval: Every 100 hours
1.
Apply 44 N (10 lb) of force to the alternator belt,
midway between the pulleys.
2.
If the deflection is not 10 mm (3/8 inch), loosen
the alternator mounting bolts (Figure 63).
g235769
Figure 61
Side Discharge Machine Shown
1. Spring-loaded idler pulley
3. Spring
2. Square hole in the idler
arm for the ratchet
4. Mower belt
8.
Ensure that the spring ends are seated in the
anchor grooves, and using the ratchet in the
square hole, install the belt around the idler
pulley (Figure 60 or Figure 61).
9.
Install the belt covers (Figure 62).
g008932
Figure 63
1. Mounting bolt
55
2. Alternator
3.
Increase or decrease the alternator-belt tension.
4.
Tighten the mounting bolts.
5.
Check the deflection of the belt again to ensure
that the tension is correct.
Controls System
Maintenance
Adjusting the
Control-Handle Position
There are 2 height positions for the control
levers—high and low. Remove the bolts to adjust the
height for the operator.
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Loosen the bolts and flange nuts installed in the
levers (Figure 64).
4.
Align the levers in the front-to-rear position by
bringing the levers together to the NEUTRAL
position, and slide them until they are aligned,
then tighten the bolts (Figure 65).
g009195
Figure 65
5.
If the ends of the levers hit against each other,
refer to Adjusting the Motion-Control Linkage
(page 56).
6.
Repeat to adjust the control levers.
Adjusting the
Motion-Control Linkage
Located on either side of the machine, below the seat,
are the pump-control linkages. Rotating the end nut
with a 1/2-inch deep socket wrench allows fine tuning
adjustments so that the machine does not move in
neutral. Any adjustments should be made for neutral
positioning only.
WARNING
g009040
Figure 64
1. Bolt
2. Handle
To adjust the motion control, you must run
the engine and turn the drive wheels. Contact
with moving parts or hot surfaces may cause
personal injury.
3. Control lever
4. Nut
Keep your fingers, hands, and clothing clear
of rotating components and hot surfaces.
56
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Push the deck-lift pedal, remove the height-of-cut
pin, and lower the mower deck to the ground
4.
Raise the rear of the machine up and support it
with jack stands (or equivalent support) just high
enough to allow the drive wheels to turn freely.
5.
Remove the electrical connection from the seat
safety switch, located under the bottom cushion
of the seat.
Note: The wheels should stop turning or slightly
creep in reverse.
Note: The switch is a part of the seat assembly.
6.
Temporarily install a jumper wire across the
terminals in the connector of the main wire
harness.
7.
Start the engine, run it at full throttle, and
disengage the parking brake.
Shut off the machine.
13.
Remove the jumper wire from the wire harness
and plug the connector into the seat switch.
14.
Remove the jack stands.
15.
Raise the deck and install the height-of-cut pin.
16.
Check and ensure that the machine does
not creep in neutral with the parking brake
disengaged.
Adjusting the
Motion-Control Damper
Note: Before starting the engine, ensure that
the parking brake is engaged and that the
motion-control levers are out. You do not have
to be in the seat.
8.
12.
You can adjust the top damper-mounting bolt to obtain
the desired motion-control lever resistance. Refer to
Figure 67 for mounting options.
Run the machine at least 5 minutes with the
drive levers at full forward speed to bring the
hydraulic fluid up to the operating temperature.
Note: The motion-control levers must be in
neutral while you are making any adjustments.
9.
Bring the motion-control levers into the NEUTRAL
position.
10.
Adjust the pump control rod lengths by rotating
the double nuts on the rod in the appropriate
direction until the wheels slightly creep in
reverse (Figure 66).
g008620
Figure 67
Right Motion Control Shown
1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must
protrude past the end of the locknut after torquing.
2. Most resistance (firmest feel)
3. Damper
4. Medium resistance (medium feel)
5. Least resistance (softest feel)
g228557
Figure 66
1. Turn here to adjust.
11.
2. Loosen here (right-hand
thread).
Move the motion-control levers to the REVERSE
position and while applying slight pressure to
the lever, allow the reverse-indicator springs to
bring the levers back to neutral.
57
Hydraulic System
Maintenance
2.
Note: Run the engine at the lowest possible
rpm to purge any air in the system.
Hydraulic System Safety
Important: Do not engage the PTO.
• Seek immediate medical attention if fluid is injected
•
•
•
•
Move the motion-control levers to the
NEUTRAL-LOCK position and start the engine.
into skin. Injected fluid must be surgically removed
within a few hours by a doctor.
Ensure that all hydraulic-fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before applying pressure to
the hydraulic system.
Keep your body and hands away from pinhole
leaks or nozzles that eject high-pressure hydraulic
fluid.
Use cardboard or paper to find hydraulic leaks.
Safely relieve all pressure in the hydraulic system
before performing any work on the hydraulic
system.
3.
Raise the deck to extend the lift cylinders, shut
off the engine, and remove the key.
4.
Raise the seat to access the hydraulic-fluid tank.
5.
Remove the hydraulic-tank cap (Figure 68).
Servicing the Hydraulic
System
g227849
Figure 68
1. Hydraulic-tank cap
Hydraulic-Fluid Specifications
3. Filler neck
2. Dipstick
Hydraulic-tank capacity: 15.1 L (16 US qt)
Recommended fluid: Toro Premium
Transmission/Hydraulic Tractor Fluid (available in
5-gallon pails or 55-gallon drums. See the Parts
Catalog or contact an authorized Toro distributor for
part numbers.)
6.
Remove the dipstick and wipe it with a clean rag
(Figure 68).
7.
Place the dipstick into the filler neck, remove it,
and check the fluid level (Figure 69).
Note: If the level is not within the notched area
Alternate fluids: If the Toro fluid is not available,
Mobil® 424 hydraulic fluid may be used.
of the dipstick, add enough high-quality hydraulic
fluid to raise the level to within the notched area.
Note: Toro does not assume responsibility for
Important: Do not overfill.
damage caused by improper substitutions.
Note: Many hydraulic fluids are almost colorless,
making it difficult to spot leaks. A red dye additive
for the hydraulic-system fluid is available in 20 ml
(2/3 fl oz) bottles. 1 bottle is sufficient for 15 to 22 L
(4 to 6 gallons) of hydraulic fluid. Order Part Number
44-2500 from your authorized Toro distributor.
Checking the Hydraulic-Fluid
Level
Service Interval: Before each use or daily
Check the hydraulic-fluid level before you first start
the engine and daily thereafter.
1. Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
g228816
Figure 69
1. Full line
58
2. Add line
8.
9.
Replace the dipstick and thread the fill cap
finger-tight onto the filler neck.
Check all hoses and fittings for leaks.
Changing the Hydraulic Fluid and
Filter
Service Interval: After the first 200 hours—Change
the hydraulic fluid and filter.
Every 400 hours—Change the hydraulic fluid
and filter if using Mobil® 424 hydraulic fluid.
Every 800 hours—Change the hydraulic
fluid and filter if using Toro Premium
Transmission/Hydraulic Tractor Fluid.
1. Disengage the PTO, move the motion-control
levers to the NEUTRAL-LOCK position, and
engage the parking brake.
2. Move the throttle lever to the SLOW position,
shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3. Raise the seat.
4. Place a large drain pan under the hydraulic
reservoir, transmission case, and the left and
right wheel motors (Figure 70).
6.
Clean the area around the hydraulic-fluid filter
and remove the filter (Figure 70).
7.
Install a new hydraulic-fluid filter and turn the
filter clockwise until the rubber seal contacts the
filter adapter, then tighten the filter an additional
2/3 to 3/4 turn.
8.
Install the 4 drain plugs.
Note: The wheel motor drain plugs are
magnetic; wipe them clean before installing.
9.
Remove the fill-port plug on the top of each
wheel motor (Figure 71).
A.
Fill each wheel motor with approximately
1.4 L (1.5 US qt) of Toro Premium
Transmission/Hydraulic Tractor Fluid.
B.
Install the fill-port plugs.
g235097
Figure 71
1. Fill port
10.
Remove the reservoir cap and dipstick from the
hydraulic-fluid tank.
11.
Add 7.6 L (8 US qt) of fluid to the reservoir.
12.
Raise the rear of machine up and support it with
jack stands (or equivalent support) just high
enough to allow the drive wheels to turn freely.
13.
Start the engine and check for fluid leaks.
g231945
Figure 70
1. Rear frame
4. Transmission case drain
plug
2. Left wheel motor drain
plug
5. Right wheel motor drain
plug
3. Hydraulic reservoir drain
plug
6. Hydraulic-fluid filter
5.
Allow the engine to run for about 5 minutes, then
shut it off.
14.
Remove the drain plugs from each area and
allow the hydraulic fluid to drain (Figure 70).
59
After 2 minutes, check the level of the hydraulic
fluid; refer to Checking the Hydraulic-Fluid Level
(page 58).
Mower Deck
Maintenance
Blade Safety
A worn or damaged blade can break, and a piece of
the blade could be thrown toward you or bystanders,
resulting in serious personal injury or death. Trying to
repair a damaged blade may result in discontinued
safety certification of the product.
1. Cutting edge
3. Wear/slot forming
• Inspect the blades periodically for wear or damage.
2. Curved area
4. Crack
g006530
Figure 72
• Use care when checking the blades. Wrap the
blades or wear gloves, and use caution when
servicing the blades. Only replace or sharpen the
blades; never straighten or weld them.
Checking for Bent Blades
Note: The machine must be on a level surface for
the following procedure.
• On multi-bladed machines, take care as rotating 1
blade can cause other blades to rotate.
Servicing the Cutting
Blades
1.
Raise the mower deck to the highest
height-of-cut position.
2.
While wearing thickly padded gloves, or other
adequate hand protection, slowly rotate the
blade into a position that allows you to measure
the distance between the cutting edge and the
level surface the machine is on (Figure 73).
To ensure a superior quality of cut, keep the blades
sharp. For convenient sharpening and replacement,
you may want to keep extra blades on hand.
Before Inspecting or Servicing the
Blades
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
g014972
Figure 73
1. Deck
2. Spindle housing
Inspecting the Blades
Service Interval: Before each use or daily
1.
Inspect the cutting edges (Figure 72).
2.
If the edges are not sharp or have nicks, remove
and sharpen the blade; refer to Sharpening the
Blades (page 62).
3.
Inspect the blades, especially in the curved area.
4.
If you notice any cracks, wear, or a slot forming
in this area, immediately install a new blade
(Figure 72).
3.
60
3. Blade
Measure from the tip of the blade to the flat
surface (Figure 74).
g014973
g014973
Figure 74
Figure 76
1. Blade (in position for measuring)
1. Opposite blade edge (in position for measuring)
2. Level surface
3. Measured distance between blade and the surface (A)
2. Level surface
3. Second measured distance between blade and surface (B)
4.
Rotate the same blade 180 degrees so that
the opposing cutting edge is now in the same
position (Figure 75).
A.
If the difference between A and B is greater
than 3 mm (1/8 inch), replace the blade with
a new blade; refer to Removing the Blades
(page 61) and Installing the Blades (page
62).
Note: If a bent blade is replaced with a
new blade, and the dimension obtained
continues to exceed 3 mm (1/8 inch), the
blade spindle could be bent. Contact an
Authorized Service Dealer for service.
B.
If the variance is within constraints, move to
the next blade.
g014974
6.
Figure 75
1. Blade (side previously measured)
Removing the Blades
2. Measurement (position used previously)
3. Opposing side of blade being moved into measurement
position
5.
Repeat this procedure on each blade.
Replace the blades if they hit a solid object, or if the
blade is out of balance or bent.
Measure from the tip of the blade to the flat
surface (Figure 76).
Note: The variance should be no more than
3 mm (1/8 inch).
61
1.
Place a wrench on the flat of the spindle shaft or
hold the blade end using a rag or thickly padded
glove.
2.
Remove the blade bolt, bushing, and blade from
the spindle shaft (Figure 77).
g000553
Figure 79
1. Blade
3.
2. Balancer
Repeat this procedure until the blade is
balanced.
Installing the Blades
1.
Install the bushing through the blade with the
bushing flange on the bottom (grass) side of the
blade (Figure 80).
g295816
Figure 77
1. Sail area of the blade
4. Bushing
2. Blade
3. Flat of the spindle shaft
5. Blade bolt
g255205
Figure 80
Sharpening the Blades
1.
1. Bushing
Use a file to sharpen the cutting edge at both
ends of the blade (Figure 78).
2.
Note: Maintain the original angle.
Install the bushing/blade assembly into the
spindle shaft (Figure 81).
Note: The blade retains its balance if the same
amount of material is removed from both cutting
edges.
g000552
Figure 78
1. Sharpen at original angle.
2.
Check the balance of the blade by putting it on a
blade balancer (Figure 79).
Note: If the blade stays in a horizontal position,
the blade is balanced and can be used.
g298850
Note: If the blade is not balanced, file some
Figure 81
metal off the end of the sail area only (Figure 78).
1. Top spindle nut
2. Flat of the spindle shaft
62
3. Blade bolt
3.
4.
• Side-Discharge Machines: 6.4 mm (1/4
Apply copper-based lubricant or grease to the
threads of the blade bolt as needed to prevent
seizing. Install the blade bolt finger-tight.
inch) higher than the front.
• Rear-Discharge Machines: should be level
Place a wrench on the flat of the spindle shaft
and torque the blade bolt to 75 to 81 N∙m (55
to 60 ft-lb).
with the front.
Leveling the Mower Deck
Note: Ensure that the mower deck is level before
matching the height of cut (HOC).
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Check tire pressure of the drive tires.
If needed, adjust to 124 kPa (18 psi).
4.
Using the deck-lift switch, move the deck height
out of the transport position (or 5-1/2 inches
(140 mm) cutting height).
g009997
Figure 83
1. Side discharge: 8.3
cm (3-1/4 inches); rear
discharge: 7.6 cm (3
inches).
4. 7.6 cm (3 inches)
2. Rear blade tip
5. Level surface
3. Front blade tip
9.
Fine-tune the adjustment nut on the front deck
lift assembly by turning it (Figure 84).
Note: To increase the height, turn the
adjustment nut clockwise; to decrease, turn
counterclockwise.
Note: If the front deck links do not have enough
adjustment to achieve accurate cut height, you
can use the single-point adjustment to gain
more adjustment.
g227689
Figure 82
1. Height-of-cut bracket
2. Height-of-cut pin
5.
Insert the height-adjustment pin into the 76 mm
(3 inches) height-of-cut location.
6.
Release the transport lock and allow the deck to
lower to the cutting height.
7.
Raise the discharge deflector (side discharge
mowers only).
8.
Measure from the level surface to the front tip of
the center blade (Figure 83).
Note: The measurement should read 7.6 mm
(3 inches).
In most conditions, the back tips on the side
blades should be adjusted as follows:
63
g232012
Figure 85
1. Single-point height
adjustment bolt
2. Front height-of-cut plate
mounting bolt
g231991
Figure 84
1. Deck adjustment
3. Adjustment nut
14.
2. Jam nut
10.
3. Rear height-of-cut plate
mounting bolt
Measure the rear blade tip height. Fine-tune the
rear adjusters as required; use the single-point
adjustment to gain more adjustment.
To adjust the single-point system, first loosen
the front and rear height-of-cut plate mounting
bolts (Figure 85).
Note: Rear-Discharge Machines Only: The
mower deck is attached in the front holes at the
factory (Figure 86). If needed, use the back
holes for further adjustment when leveling the
mower deck.
• Side-Discharge Machines: the rear tips
of the side blades should measure 8.3 cm
(3-1/4 inches).
• Rear-Discharge Machines: the rear tips of
the side blades should measure 7.6 cm (3
inches).
11.
Measure until all 4 sides are the correct
height. Tighten all the nuts on the deck-lift arm
assemblies.
12.
Lower the discharge deflector (side-discharge
mowers only).
13.
If the 4 deck adjusters do not have enough
adjustment to achieve the accurate height of
cut with the desired rake, you can adjust the
single-point system (Figure 85).
g025558
Figure 86
1. Mower deck
2. Front hole
15.
64
3. Back hole
If the deck is too low, tighten the single-point
adjustment bolt by rotating it clockwise. If
the deck is too high, loosen the single-point
adjustment bolt by rotating it counterclockwise
(Figure 87).
Note: Loosen or tighten the single-point
adjustment bolt enough to move the
height-of-cut plate mounting bolts at least 1/3
the length of the available travel in their slots.
This regains some up and down adjustment on
each of the 4 deck links.
g009042
Figure 87
1. Single-point-adjustment bolt
16.
Tighten the 2 bolts at the bottom of the
height-of-cut plate (Figure 85).
Note: For most conditions, adjust the black
blade tip 6.4 mm (1/4 inch) higher than the front.
17.
Torque the 2 bolts to 91 to 113 N∙m (67 to 83
ft-lb).
18.
Measure until all 4 sides are the correct
height. Tighten all the nuts on the deck lift arm
assemblies.
65
Replacing the Grass
Deflector
position and ensure that it rotates into the
full down position.
Side-Discharge Machines Only
WARNING
An uncovered discharge opening could allow
the machine to throw objects toward you or
bystanders, resulting in serious injury. Also,
contact with the blade could occur.
Never operate the machine unless you install
a mulch plate, discharge deflector, or grass
collection system.
1.
Remove the locknut, bolt, spring, and spacer
holding the deflector to the pivot brackets
(Figure 88).
2.
Remove the damaged or worn grass deflector
(Figure 88).
g015594
Figure 88
1. Bolt
5. Spring installed
2. Spacer
6. Grass deflector
3. Locknut
7. J-hook end of spring
4. Spring
3.
Place the spacer and the spring onto grass
deflector.
4.
Place 1 J-hook end of the spring behind the
deck edge.
Note: Make sure that 1 J-hook end of the
spring is installed behind the deck edge before
installing the bolt as shown in Figure 88.
5.
Install the bolt and the nut.
6.
Place 1 J-hook end of the spring around the
grass deflector (Figure 88).
Important: The grass deflector must be able
to rotate. Lift the deflector up to the full open
66
Cleaning
Cleaning the Engine and
Exhaust System Area
Service Interval: Before each use or daily—Clean the
engine and exhaust system area.
Important: Do not use water to clean the engine.
Use low-pressure compressed air. See the engine
owner's manual.
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Clean around the flywheel, cylinder head,
injectors, and injector pump.
4.
Clean all debris from the exhaust system area.
5.
Wipe up any excessive grease or oil around the
engine and exhaust area.
Cleaning the Machine and
Mower Deck
Service Interval: Before each use or daily
1.
Park the machine on a level surface, disengage
the blade-control switch (PTO), and engage the
parking brake.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
Clean off any oil, debris, or grass build-up on
the machine and mower deck, especially under
the deck-belt shields, around the fuel tank, and
around the engine and exhaust area.
4.
Raise the mower deck to the TRANSPORT
position.
5.
Clean out any grass build-up from the underside
of deck and in the discharge deflector.
Disposing of Waste
Engine oil, batteries, hydraulic fluid, and engine
coolant are pollutants to the environment. Dispose of
these according to your state and local regulations.
67
Storage
13.
Storage Safety
Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows:
A.
• Shut off the engine, remove the key, wait for all
moving parts to stop, and allow the machine to
cool before storing it.
• Do not store the machine or fuel near flames or
drain the fuel indoors.
Add a petroleum-based
stabilizer/conditioner to fuel in the
tank. Follow mixing instructions from
the stabilizer manufacturer. Do not use
an alcohol-based stabilizer (ethanol or
methanol).
Note: A fuel stabilizer/conditioner is most
• Remove the key and store it in a safe place out
effective when mixed with fresh fuel and
used at all times.
of the reach of children.
Cleaning and Storage
B.
Run the engine to distribute conditioned fuel
through the fuel system for 5 minutes.
1.
Disengage the blade-control switch (PTO), and
engage the parking brake.
C.
Shut off the engine, allow it to cool, and
drain the fuel tank.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
D.
Start the engine and run it until it stops.
E.
Dispose of fuel properly. Recycle the fuel
according to local codes.
3.
Remove grass clippings, dirt, and grime from the
external parts of the entire machine, especially
the engine and hydraulic system. Clean dirt and
chaff from the outside of the engine cylinder
head fins and blower housing.
Important: Do not store fuel containing
stabilizer/conditioner longer than
the duration recommended by the
fuel-stabilizer manufacturer.
Important: You can wash the machine with
14.
mild detergent and water. Do not pressure
wash the machine. Avoid excessive use
of water, especially near the control panel,
engine, hydraulic pumps, and motors.
Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
15.
Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service Dealer.
16.
Store the machine in a clean, dry garage or
storage area. Remove the key from the switch
and keep it out of reach of children or other
unauthorized users. Cover the machine to
protect it and keep it clean.
4.
Check the parking brake operation; refer to
Operating the Parking Brake (page 24).
5.
Service the air cleaner; refer to Servicing the Air
Cleaner (page 42).
6.
Grease the machine; refer to Greasing the
Machine (page 40).
7.
Change the crankcase oil; refer to Servicing the
Engine Oil (page 43).
8.
Check the tire pressure; refer to Checking the
Tire Pressure (page 49).
9.
Change the hydraulic filters; refer to Changing
the Hydraulic Fluid and Filter (page 59).
10.
Charge the battery; refer to Charging the Battery
(page 47).
11.
Scrape any heavy buildup of grass and dirt
from the underside of the mower, then wash the
mower with a garden hose.
Note: Run the machine with the blade-control
switch (PTO) engaged and the engine at high
idle for 2 to 5 minutes after washing.
12.
Check the condition of the blades; refer to
Servicing the Cutting Blades (page 60).
68
Troubleshooting
Problem
The starter does not crank.
The engine does not start, starts hard, or
fails to keep running.
Possible Cause
1. The blade-control switch is engaged.
1. Disengage the blade-control switch.
2. The parking brake is disengaged.
3. The motion-control levers are not in
the NEUTRAL-LOCK position.
4. You are not sitting in the operator’s
seat.
5. The battery is dead.
6. The electrical connections are
corroded or loose.
7. A fuse is blown.
8. A relay or switch is damaged.
2. Engage the parking brake.
3. Move the motion-control levers
outward to the NEUTRAL-LOCK position.
4. Sit on the operator’s seat.
5. Charge the battery.
6. Check the electrical connections for
good contact.
7. Replace the fuse.
8. Contact an Authorized Service Dealer.
1. The fuel tank is empty.
1. Fill the fuel tank.
2. The fuel-shutoff valve is closed.
3. The oil level in the crankcase is low.
4. The throttle is not in the correct
position.
2. Open the fuel-shutoff valve.
3. Add oil to the crankcase.
4. Be sure that the throttle control is
midway between the SLOW and FAST
positions.
5. Replace the fuel filter.
6. Contact an Authorized Service Dealer.
5. There is dirt in fuel filter.
6. There is dirt, water, or stale fuel is in
the fuel system.
7. The air cleaner is dirty.
10. The relay or switch is broken.
7. Clean or replace the air-cleaner
element.
8. Check the seat switch indicator.
Replace the seat if needed.
9. Check the electrical connections for
good contact. Clean the connector
terminals thoroughly with electrical
contact cleaner, apply dielectric
grease, and connect.
10. Contact an Authorized Service Dealer.
1. The engine load is excessive.
1. Reduce the ground speed.
2. The air cleaner is dirty.
3. The oil level in the crankcase is low.
4. The cooling fins and the air passages
above the engine are plugged.
5. The vent hole in the fuel cap is plugged.
6. There is dirt in the fuel filter.
7. There is dirt, water, or stale fuel in the
fuel system.
2. Clean the air-cleaner element.
3. Add oil to the crankcase.
4. Remove the obstruction from the
cooling fins and the air passages.
5. Clean or replace the fuel cap.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
1. The engine load is excessive.
1. Reduce the ground speed.
2. The oil level in the crankcase is low.
3. The cooling fins and air passages
under the engine-blower housing are
plugged.
4. The air cleaner is dirty.
2. Add oil to the crankcase.
3. Remove the obstruction from the
cooling fins and air passages.
8. The seat switch is not functioning
properly.
9. The electrical connections are
corroded, loose or faulty.
The engine loses power.
The engine overheats.
5. Dirt, water, or stale fuel is in the fuel
system.
The machine pulls to the left or right (with
the motion-control levers fully forward).
Corrective Action
4. Clean or replace the air-cleaner
element.
5. Contact an Authorized Service Dealer
1. The tracking needs adjustment
1. Adjust the tracking.
2. The tire pressure in the drive tires is
not correct.
2. Adjust the tire pressure in the drive
tires.
69
Problem
The machine does not drive.
The machine vibrates abnormally.
The cutting height is uneven.
Possible Cause
1. The bypass valves are not closed tight.
1. Tighten the bypass valves.
2. The pump belt is worn, loose, or
broken.
3. The pump belt is off a pulley.
4. The idler spring is broken or missing.
5. The hydraulic fluid level is low or too
hot.
2. Change the belt.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to the reservoirs or
let it cool down.
1. The cutting blade(s) is/are bent or
unbalanced.
1. Install new cutting blade(s).
2. The blade mounting bolt is loose.
3. The engine mounting bolts are loose.
4. The engine pulley, idler pulley, or blade
pulley is loose.
5. The engine pulley is damaged.
6. The blade spindle is bent.
7. The motor mount is loose or worn.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Contact an Authorized Service Dealer.
1. The blade(s) is not sharp.
1. Sharpen the blade(s).
2. A cutting blade(s) is/are bent.
3. The mower is not level.
2. Install a new cutting blade(s).
3. Level the mower from side-to-side and
front-to-rear.
4. Adjust the anti-scalp wheel height.
4. An anti-scalp roller (if applicable) is not
set correctly.
5. The underside of the mower deck is
dirty.
6. The tire pressure is incorrect.
7. A blade spindle is bent.
The blades do not rotate.
Corrective Action
5. Clean the underside of the mower
deck.
6. Adjust the tire pressure.
7. Contact an Authorized Service Dealer.
1. The mower deck belt is damaged,
worn, loose, or broken.
1. Install a new deck belt.
2. The mower deck belt is off the pulley.
2. Install the mower belt on the deck
pulley and check the idler pulley, idler
arm, and spring for correct position
and function.
3. Check the belt tension or install a new
belt.
4. Replace the spring.
3. The pump drive belt is worn, loose, or
broken.
4. The idler spring is broken or missing.
70
Electrical Schematic—Machine with Horizon Display Monitor (Rev. A)
PWR
GND
CAN HI
CAN LOW
TRANS TEMP
PTO SWITCH
KEY S
CONFIG
NEUTRAL
KEY A
CAN HI
CAN LOW
BRAKE
OPC
GND
GND
CLUTCH
PWR TO RUN
START
B+
B+
ALARM
FUEL PUMP PWR
P04
1
2
3
4
P03
1
2
3
4
5
6
7
8
9
10
11
12
P02
1
12
3
4
5
6
7
8
9
10
11
2
P01
1
2
3
4
5
6
7
8
9
10
11
12
RED/WHITE
BLACK
YELLOW
GREEN
GRAY/RED
VIOLET/WHITE
BLUE
WHITE/GRAY
GREEN/YELLOW
RED/WHITE
YELLOW
GREEN
GREEN/BROWN
GREEN/GRAY
BLACK
BLACK
VIOLET/RED
RED/GREEN
BLUE/BLACK
RED-GREEN
RED-GREEN
GRAY/VIOLET
RED-GREEN
1 2
1
SP5
TRANSMISSION
TEMP SENSOR
P05
1
SP6
BLACK
GND
PWR
SW PWR
CAN LOW
CAN HI
P06
BLACK
RED/GREEN
RED/WHITE
GREEN
YELLOW
1
SP4
CLUTCH
1 2 4 9 5 3 8 6 12 7 10 11
TO CONNECTOR
P07 ON HARNESS
1
SP3
P16 A B C
ACC
1
SP2
ORANGE
P17 A B
BLACK
VIOLET/RED
RED/GREEN
BLUE/BLACK
GRAY/VIOLET
BLACK
BLACK
RED/GREEN
GREEN
YELLOW
BLACK
1 2 3 4 5 6
RED/GREEN
ORANGE/RED
RED/WHITE
MCU GRAY
CONNECTOR
MCU BLACK
CONNECTOR
MCU GREEN
CONNECTOR
LDU
P18
BLACK
WHITE /GREEN
RAISE S2
P08 2 1
1
SP1
PWR
RAISE = PWR to S1 + S2
LOWER= PWR to S1
LIFT/LOWER
SWITCH
P07 8 7 6 5 4 3 2 1
RED/WHITE
ORANGE
71
FUSED PWR
ACC PWR
PWR SW
BLACK
ORANGE
LOWER S1
P09 2 1
1
SP7
P14
A
B
C
P13
1
2
P12
1
2
P11
1
2
P10
1
2
RED/WHITE
GREEN/YELLOW
GREEN/YELLOW
RED/WHITE
GREEN/BROWN
RED/WHITE
GREEN/GRAY
PWR
OUT
GND
P15
A
B OFF= NONE
C ACC= A, C, D
D START= B, C, D
VIOLET/WHITE
BLACK
RED/WHITE
ORANGE
BLUE
RED/WHITE
RED/GREEN
LH
RH
BRAKE
NEUTRAL NEUTRAL SWITCH
PWR TO RUN
START
ALARM
GND
GND
FUEL PUMP PWR
CAN LOW
CAN HIGH
GND
ACC PWR
ACC SIGNAL
RED/WHITE
SERVICE
CONNECTOR
Schematics
KEY
SWITCH
PTO SWITCH
SEAT
SWITCH
g229105
J02
B+ @ BATTERY 1
CLAMP
J01
OIL
PRESSURE 1
SWITCH
P03
STARTER A
B
B+
C
RED
RED
RED
RED
BROWN
YELLOW
ORANGE
WHITE
BLUE
BROWN
RED
YELLOW
VIOLET
SP06
SP02
2 1
P04
AIR
FILTER
SW
RED/WHITE
GRAY/BROWN
P02
7
RED
26 GREEN
25 BLACK
8
RED
37 BLUE
52 BLACK
39
VIOLET
54
ORANGE
38 BLACK
11 BLUE
51 BROWN
20
BLUE
19
YELLOW
29
50
28
60
59 YELLOW
34
12
30
48
18
47
17
33
16
4
5
SP12
ALTERNATOR
J03 1 P05 1 2
B
IG
YELLOW
YELLOW
VIOLET
VIOLET
WHITE
P24
1
2
3
4
5
6
7
8
9
10
11
12
ORANGE
5VS
PRAIL
ANALOG GND
5VS
CMSPD
ANALOG GND
CKSPD
CKSPD
ANALOG GND
TF0
ANALOG GND
IVDCM-L
IVDCM-H
ANALOG GND
ENGINE
UB3
CONTROLLER
TW
(60 PIN)
UB2
AIR TEMP
DPF-M4
PDPFH
UB5
INJ3-H
INJ3-L
INJ2-H
INJ2-L
INJ1-H
INJ1-L
MPROP-H
HPPSO-L
1 2
P07
BLACK
FUEL PUMP
P06
BROWN
GREEN
BLACK
RED/WHITE
SP09
SP10
SP03
1 2 9 8 11 10 3 4 6 12 5 7
TO CONNECTOR P06 ON HARNESS
ORANGE
SP05
1 2 P09 1 2 3 4 5 6
P08
YANMAR
12V
CAN
POWER
CHECKER
PORT
SP08
GLOW
(85) RELAY
J06
(86) (30)(87)
P19 1 2 3 5 6 7 8 9
RED
1
BLACK
TO HARNESS B CONNECTOR 40
P20
YELLOW
BLUE
P21 8 7 6 5 4 3 2 1
SP11
ALARM
A B C
P10
B A
P11
REVERSE
POLARITY
PROTECTION
DIODE
BLUE
TO HARNESS B CONNECTOR 41
ORANGE
RED/GREEN
RED/GREEN
FUSED PWR
ACC PWR
RED
P22 12 11 10 9 8 7 6 5 4 3 2 1
BLUE
GREEN
GRAY/VIOLET
YELLOW
GREEN
ALARM
SP04
SP01
EGR RELAY
DPF PRESSURE
FLYBACK
(87A)
SENSOR
DIODE
(30)(85) (87)(86)
P17 1 2 3 4 5 P16 A B P15 1 2 3 4 5 6
GREEN
TO HARNESS B CONNECTOR 42
W099 TXL10BK
1 2 3 4 5 6 7 8 9 10 11 12
RED
BLACK
STARTER
"S" START RELAY
(87A)
1
(30)(85) (87)(86)
P18 1 2 3 4 5
BLACK
BLUE
GLOW
PLUGS
BLACK
P14
DPF
P13 1 2
1 2
INLET TEMP
BLACK
WHITE
MIDDLE TEMP
BLACK
BROWN
87a
87
30
86
85
COIL
RELAY DIAGRAM
GREEN
P23
WHITE
YELLOW
BLACK
BLACK
RED/WHITE
Electrical Schematic—Yanmar Engine 3TNV80FT (Rev. A)
CAN HIGH
CAN LOW
TO HARNESS B
CONNECTOR 43
SW PWR
GND
GND
PWR TO RUN
FUEL PUMP
72
BLACK
BLUE
GRAY/VIOLET
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
ORANGE
ORANGE
VIOLET
WHITE
RED
BLACK
GREEN
VIOLET
WHITE
RED
RED
RED
VIOLET
BLUE
YELLOW
BLUE
RED
BLUE
BLACK
BLUE
RED
GREEN
BLACK
RED/GREEN
RED
RED
RED
RED/GREEN
RED
RED
RED
REGEN
D-GND
EGR TEMP/TEGR
ANALOG GND/A_GND
PDPF
5VS
EXH TEMP/TEXMH
DPF INLET TEMP/TOPFI
DPF MIDDLE TEMP/TOPFM
UB2
STARTSW
UB5
START RELAY/STR_RLY(D_UB5)
GLOW RELAY/SAID_RLY
VB
VB
VB
CAN1H
CAN1L
CAN2H
CAN2L ENGINE CONTROLLER
(94 PIN)
5VS
P. EGR
P. EGR L.
ANALOG GND/A_GND
LOW OIL LAMP/LOPSW
CHGSW
NO REGEN SW.
TFAIR
ANALOG GND/A_GND
5VS
IVPS
ANALOG GND/A_GND
IGN SW.
5VS
ANALOG GND/A_GND
APS1
GND
GND
GND
UB3
ACL SW
ENGINE FUSE 25A
CHASSIS FUSE 15A
POWER
PORT
FUSE 15A
ACC
FUSE 15A
1 J05 ENGINE (CONNECT @ BATT NEG)
GROUND
1 J04ENGINE ECU
CASE GROUND
P01
18
65
33
77
63
24
56
81
80
68
35
73
28
70
5
3
1
54
76
75
53
45
85
39
74
15
66
31
79
21
23
20
52
88
43
62
61
2
4
6
90
41
P12
1
2
3
4
5
6
7
8
9
10
11
12
POWER DISTRIBUTION
MODULE
g229107
BATTERY
CLAMP J02 1
B+
A
STARTER
P03 B
B+
C
OIL TEMP P21 1
SENSOR
2
ENGINE
SPEED P13 1
2
SENSOR
6
5
4
RACK
P02
ACT
3
2
1
RED
RED/GREEN
RED/GREEN
BLACK
BLACK
BLACK
SP11
J03
BLACK
RED/GREEN
ALTERNATOR
1 P05 1 2
B
IG L
BLUE/GREEN
RED/GREEN
BLACK
ORANGE
SP2
SP1
SP9
BLUE/RED
BLACK
TO CONNECTOR
P06 ON HARNESS
1
2 1
1 2 P07 1 2 4 9 5 3 8 6 12 7 10 11
J01
P04
P06
OIL
FUEL
AIR
FILTER PRESSURE PUMP
SW
SW
BLACK
RED/WHITE
SP7
P09
SP10
BLUE/RED
BLUE/YELLOW
SP6
FLY BACK
DIODE
P16
A B
1 2 3 4 5 6
SP4
SP3
BLACK
BLUE/RED
STARTER START RELAY
SIGNAL
30 85 87A 87 86
J06
1 P18 1 2 3 4 5
YANMAR
CAN CHECKER
BLACK
PREHEAT RELAY
GLOW
30 85 87A 87 86
P20
P14 3 2 4 5 1
1
COOLANT
TEMP
SENSOR
P11
1 2
A B C
P10
ALARM
1 2
P08
12V
POWER
PORT
BLACK
GREEN
1
J05
ENGINE
GROUND
SP5
ATM PRESSURE
SENSOR
P17
1 2 3
SP12
BLACK
ACTUATOR RELAY
30 85 87A 87 86
P15 1 2 3 4 5
RED/GREEN
RED/GREEN
FUSED PWR
ACC PWR
SW PWR
BLACK
RED/WHITE
BLUE/YELLOW
YELLOW/VIOLET
BLACK
BLACK
PWR TO RUN
START
ALARM
GND
GND
FUEL PUMP
GREEN
YELLOW
CAN LOW
CAN HIGH
BLACK
YELLOW
GREEN
BLACK
PWR
CAN HIGH
CAN LOW
GND
BLACK
BLACK
73
BLACK
Electrical Schematic—Yanmar Engine 3TNV88C (Rev. A)
g229106
SP8
BLACK
RED/GREEN
BROWN
ORANGE
BLUE/GRAY
BLACK
RED/YELLOW
GREEN
YELLOW
WHITE
GREEN
BLACK
GREEN
BLACK
GRAY/ORANGE
YELLOW
BLACK
ORANGE
YELLOW
GRAY/WHITE
RED/WHITE
BLUE
GRAY/BROWN
RED/GREEN
RED/GREEN
RED
RED
RED
RED/GREEN
RED/GREEN
RED/GREEN
RED
RED/GREEN
RED
P01
1 4A
2 4B
3 4C
4 4D
5 4E APP_IP5
6 4F
7 4GIGN SW
8 4H START SW
9 4J
10 4K
11 3A
12 3B
13 3C
14 3D APP_IP2
15 3E
16 3F RET
17 3G
18 3H NRPW_GND
19 3J NRPW
20 3K APD_0P1
21 2A
22 2B
ENGINE
23 2C
CONTROLLER
24 2D
(48 PIN)
25 2E
26 2F
27 2G
28 2H GNDA
29 2J
30 2K RECAN
31 1A
32 1B
33 1C RACK_RLY
34 1D MAIN_RLY
35 1E
36 1F RPS
37 1G
38 1H
39 1J CAN LOW
40 1KCAN HIGH
41 4L
42 4M RACK_SOL
43 3L AVB
44 3M AIR_HT_RLY
45 2L GND
46 2M
47 1L GND
48 1M VB
P12
1
15A ACC FUSE
2
3
POWER PORT
4
FUSE 15A
5 (5) N.O.
POWER
6 (2)
DISTRIBUTION
7
MODULE
FUSE 15A
8
CHASSIS
COIL
9
FUSE 10A
10
MAIN
11
12 (3) COMMON
Notes:
California Proposition 65 Warning Information
What is this warning?
You may see a product for sale that has a warning label like the following:
WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov.
What is Prop 65?
Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into
California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other
reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to
inform the public about exposure to these chemicals.
Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with
the product. Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the
California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is ‘safe’ or ‘unsafe.’” Many of these
chemicals have been used in everyday products for years without documented harm. For more information, go to https://oag.ca.gov/prop65/faqs-view-all.
A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2)
has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.
Does this law apply everywhere?
Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not
limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order
retailers provide Prop 65 warnings on their websites or in catalogs.
How do the California warnings compare to federal limits?
Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning
at levels that are far lower than federal action limits. For example, the Prop 65 standard for warnings for lead is 0.5 μg/day, which is well below
the federal and international standards.
Why don’t all similar products carry the warning?
•
•
Products sold in California require Prop 65 labelling while similar products sold elsewhere do not.
•
•
The enforcement of Prop 65 is inconsistent.
A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies
making similar products may have no such requirement.
Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a
product does not mean that the product is free of listed chemicals at similar levels.
Why does Toro include this warning?
Toro has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and
use. Toro provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of
exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from Toro products may be negligible or well within the
“no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these
warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.
Rev A