Toro Z Master Professional 7000 Series Riding Mower, With 132cm TURBO FORCE Side Discharge Mower Riding Product Operator's Manual

Form No. 3417-850 Rev B
Z Master® Professional 7000
Series Riding Mower
With 132cm or 152cm TURBO FORCE®
Mower
Model No. 74264TE—Serial No. 402080000 and Up
Model No. 74265TE—Serial No. 402000000 and Up
Model No. 74279TE—Serial No. 402000000 and Up
Register at www.Toro.com.
Original Instructions (EN)
*3417-850* B
Gross or Net Torque: This product complies with
all relevant European directives; for details, please
see the separate product specific Declaration of
Conformity (DOC) sheet. 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.
Please refer to the engine manufacturer’s information
included with the machine.
g248729
Figure 1
Introduction
1. Model and serial number location
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. It is not designed
for cutting brush or for agricultural uses.
Model No.
Serial No.
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.
This manual identifies potential hazards and has
safety messages identified by the safety-alert symbol
(Figure 2), which signals a hazard that may cause
serious injury or death if you do not follow the
recommended precautions.
You may contact Toro directly at www.Toro.com
for product safety and operation training materials,
accessory information, help finding a dealer, or to
register your product.
For the Operator’s Manual, the complete warranty
details, or to register your product, use the QR
code or visit www.Toro.com. You may also call us
at 1-888-384-9939 to request a written copy of the
product warranty.
g000502
Figure 2
Safety-alert symbol
This manual uses 2 words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
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.
© 2018—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
Engine Maintenance ........................................... 46
Engine Safety ................................................... 46
Servicing the Air Cleaner .................................. 46
Servicing the Engine Oil.................................... 47
Fuel System Maintenance ................................... 51
Servicing the Fuel Filter and Water
Seperator ...................................................... 51
Servicing the Fuel Tank..................................... 52
Electrical System Maintenance ........................... 53
Electrical System Safety ................................... 53
Servicing the Battery......................................... 53
Servicing the Fuses .......................................... 54
Drive System Maintenance .................................. 55
Adjusting the Tracking ...................................... 55
Checking the Tire Pressure............................... 55
Checking the Wheel-Hub Slotted Nut................ 56
Adjusting the Caster-Pivot Bearing ................... 56
Servicing the Gearbox ...................................... 56
Adjusting the Electric Clutch ............................. 57
Cooling System Maintenance .............................. 59
Servicing the Cooling System ........................... 59
Brake Maintenance ............................................. 60
Adjusting the Parking Brake.............................. 60
Belt Maintenance ................................................ 61
Inspecting the Belts .......................................... 61
Replacing the Mower Belt ................................. 61
Replacing the Mower Belt ................................. 62
Replacing the PTO-Drive Belt ........................... 63
Replacing the Pump Drive Belt ......................... 64
Replacing and Tensioning the Alternator
Belt................................................................ 64
Controls System Maintenance ............................. 65
Adjusting the Control Handle Neutral
Position ......................................................... 65
Hydraulic System Maintenance ........................... 66
Hydraulic System Safety................................... 66
Servicing the Hydraulic System ........................ 66
Setting the Hydraulic Pump Neutral
Position ......................................................... 69
Mower Deck Maintenance.................................... 71
Leveling the Mower at 3 Positions ..................... 71
Servicing the Cutting Blades ............................. 74
Replacing the Grass Deflector .......................... 76
Cleaning .............................................................. 77
Cleaning under the Mower Deck ....................... 77
Disposing of Waste........................................... 77
Storage ................................................................... 78
Storage Safety.................................................. 78
Cleaning and Storage ....................................... 78
Troubleshooting ...................................................... 79
Schematics ............................................................. 81
Safety ....................................................................... 4
General Safety ................................................... 4
Slope Indicator ................................................... 5
Safety and Instructional Decals .......................... 6
Product Overview ................................................... 16
Controls ........................................................... 16
Before Operation ................................................. 18
Before Operation Safety ................................... 18
Performing Daily Maintenance.......................... 18
Adding Fuel ...................................................... 18
Breaking in a New Machine .............................. 20
Using the Rollover-Protection System
(ROPS) ......................................................... 20
Using the Safety-Interlock System .................... 21
Positioning the Seat.......................................... 22
Unlatching the Seat .......................................... 22
Changing the Seat Suspension......................... 22
During Operation ................................................. 23
During Operation Safety ................................... 23
Operating the Parking Brake............................. 25
Operating the Mower Blade-Control Switch
(PTO) ............................................................ 25
Operating the Throttle....................................... 25
Starting and Shutting Off the Engine ................. 26
Using the Motion-Control Levers....................... 27
Driving the Machine .......................................... 27
Using the Side Discharge ................................. 29
Adjusting the Height of Cut ............................... 29
Adjusting the Anti-Scalp Rollers........................ 30
Adjusting the Anti-Scalp Rollers........................ 31
Adjusting the Skid(s)......................................... 32
Adjusting the Flow Baffle Cam Locks ................ 32
Positioning the Flow Baffle................................ 33
Operating with the Overheat Sensor ................. 34
Operating Tips ................................................. 34
After Operation .................................................... 35
After Operation Safety ...................................... 35
Using the Fuel-Shutoff Valve............................. 35
Pushing the Machine by Hand .......................... 35
Transporting the Machine ................................. 36
Using the Z StandTM.......................................... 38
Maintenance ........................................................... 40
Recommended Maintenance Schedule(s) ........... 40
Pre-Maintenance Procedures .............................. 41
Maintenance Safety.......................................... 41
Releasing the Mower-Deck Curtain .................. 42
Removing the Sheet-Metal Guard..................... 42
Lubrication .......................................................... 42
Greasing the Machine....................................... 42
Greasing the Front Caster Pivots ...................... 42
Adding Grease ................................................. 42
Adding Light Oil or Spray Lubrication ................ 43
Adding Light Oil or Spray Lubrication ................ 43
Greasing the Mower Deck and Belt
Idlers ............................................................. 44
Lubricating the Caster-Wheel Hubs .................. 45
3
Safety
This machine has been designed in accordance with
EN ISO 5395:2013.
General Safety
This product is capable of amputating hands and
feet and of throwing objects. Always follow all safety
instructions to avoid serious personal injury.
Using this product for purposes other than its intended
use could prove dangerous to you and bystanders.
• Always keep the roll bar in the fully raised and
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.
• Read and understand the contents of this
Operator’s Manual before starting the engine.
• Do not put your hands or feet near moving
components of the machine.
• Do not operate the machine without all guards
and other safety protective devices in place and
working on the machine.
• Keep children and bystanders out of the operating
area. Never allow children to operate the machine.
• Stop the machine, shut off the engine, and remove
the key before servicing, fueling, or unclogging
the machine.
Improperly using or maintaining this machine can
result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety-alert symbol, which means
Caution, Warning, or Danger—personal safety
instruction. Failure to comply with these instructions
may result in personal injury or death.
You can find additional safety information where
needed throughout this manual.
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 a safe
distance 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.
decal93-7010
93-7010
1. Thrown object hazard—keep bystanders a safe distance
away from the machine.
2. Thrown object hazard, mower—keep the deflector in place.
3. Cutting/dismemberment of hand or foot—stay away from
moving parts.
10. Contains lead; do not
discard
decal93-7818
93-7818
1. Warning—read the Operator's Manual for instructions on
torquing the blade bolt/nut to 115-149 N∙m (85-110 ft-lb).
decaloemmarkt
Manufacturer's Mark
1. Indicates the blade is identified as a part from the original
machine manufacturer.
decal93-8069
93-8069
1. Hot surface/burn hazard—stay a safe distance away from
the hot surface.
decal58-6520
58-6520
decal98-1977
1. Grease
98-1977
1. Entanglement hazard, belt—stay away from moving parts.
6
decal98-4387
98-4387
1. Warning—wear hearing protection.
decal107-3069
107-3069
decal104-2449
104-2449
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 fully 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.
decal107-2114
107-2114
7
decal107-3962
107-3962
1. Height of cut in millimeters
decal107-3961
107-3961
1. Height of cut in millimeters
decal107-3964
107-3964
1. Warning—do not use drugs or alcohol.
3. Warning—engage the parking brake,
shut off the engine, and remove the
key before leaving the machine.
2. Warning—read the Operator's Manual
and receive training.
4. Warning—wear hearing protection.
8
5. Read the Operator's Manual.
decal107-3969
107-3969
1. Warning—read the Operator's Manual.
2. Crushing hazard, mower—engage the parking brake, shut
off the engine, and remove the key before working under
the mower.
decal107-3968
107-3968
1. Disengage
3. Parking brake
2. Engage
decal107-7719
107-7719
1. Cutting/dismemberment hazard, fan and entanglement
hazard, belt—stay away from moving parts.
2. Before starting the engine, clean grass and debris from the
mower belt and pulleys, insert the key, and start the engine.
decal107-9309
107-9309
1. Warning—read the Operator's Manual for information on charging the battery; contains lead; do not discard.
2. Read the Operator's Manual.
decal108-5957
decal108-5955
108-5957
108-5955
9
decal108-5981
108-5981
decal110-0820
110-0820
1. Fast
5. Warning—read the Operator's Manual.
2. Slow
6. Poison and caustic liquid/chemical burn hazard—keep
children a safe distance from the battery.
3. Neutral
7. Explosion hazard—no fire, open flames, or smoking; avoid
sparks.
4. Reverse
8. To unlock the traction drive, turn the bypass valve 1 complete
revolution counterclockwise using a 5/8 inch or 16 mm
wrench.
decal110-2067
110-2067
decal110-2068
110-2068
Side Discharge Machines Only
1. Read the Operator's Manual.
10
decal112-9028
112-9028
1. Warning—stay away from moving parts; keep all guards in
place.
decal110-3852
110-3852
1. Remove the key from
the key switch and read
the instructions before
servicing or performing
maintenance.
2. Continuous tone signals
the user that the engine is
overheating.
decal114-9600
114-9600
1. Read the Operator's Manual.
decal110-3853
110-3853
1. Cutting/dismemberment
hazard, fan and
entanglement hazard,
belt.
2. Remove the key from
the key switch and read
the instructions before
servicing or performing
maintenance.
decal115-4212
115-4212
1. Hydraulic-fliud level
3. Warning—do not touch the
hot surface.
2. Read the Operator's
Manual.
decal112-3858
112-3858
Rear Discharge Machines Only
1. Read the Operator's
Manual.
3. Remove the key from
the key switch before
adjusting the height of cut.
2. Read the instructions
before servicing or
performing maintenance.
4. Height-of-cut settings.
decal116-5610
116-5610
11
1. Hour meter
2. Power take-off (PTO)
4. Neutral
5. Operator-presence switch
3. Parking brake
6. Battery
decal117-3848
117-3848
Rear Discharge Machines Only
1. Thrown object hazard—keep bystanders a safe distance
away from the machine.
2. Thrown object hazard, mower-do not operate the machine
without the deflector, discharge cover, or grass collection
system in place.
decal121-7562
121-7562
3. Cutting/dismemberment of hand or foot—stay away from
moving parts; keep all guards and shields in place.
1. Push to start
4. Variable speed control
2. Read the Operator’s
Manual for more
information on preheating
the engine.
5. Fast
3. Slow
decal119-0397
119-0397
decal126-2055
126-2055
1. Wheel lug nut torque 129 N∙m (95 ft-lb) (4x)
2. Wheel hub nut torque 319 N∙m (235 ft-lb)
3. Read and understand the Operator’s Manual before
performing any maintenance, check torque after first 100
hours then every 500 hours thereafter.
decal119-0398
119-0398
12
decal127-0326
127-0326
Side Discharge Machines Only
3. Remove the key and
read the Operator's
Manual before performing
maintenance or servicing
the machine.
1. Read the Operator's
Manual.
2. Height of cut
decal131-4036
131-4036
1. Maximum draw bar pull 36
kg (80 lb).
2. Read the Operator's
Manual.
13
decal132-0871
132-0871
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 those conditions
on that day and at that site. Changes in the terrain can result in a change in slope operation for the machine. If possible, keep the
cutting units lowered to the ground while operating the machine on slopes. Raising the cutting units while operating on slopes can
cause the machine to become unstable.
4. Ramp hazard—when loading onto a trailer, do not use dual
ramps; only use a singular ramp wide enough for the machine
and that has an incline less than 15°; back up the ramp (in
reverse) and drive forward off the ramp.
1. Warning—read the Operator’s Manual; do not operate this
machine unless you are trained; wear hearing protection.
5. Bodily harm hazard—do not carry passengers; look behind
2. Cutting, dismembering, and entanglement hazard—keep
you when mowing in reverse.
hands away from moving parts; keep all guards and shields in
place.
3. Thrown object hazard—keep bystanders away.
6. Tipping hazard on slopes—do not use on slopes near open
water; do not use on slopes greater than 15°.
14
decal136-5519
136-5519
Rear Discharge Machines Only
decal136-5510
136-5510
Side Discharge Machines Only
1. Remove the key and
read the Operator's
Manual before performing
maintenance.
2. Grease point
1. Remove the key and
read the Operator's
Manual before performing
maintenance.
2. Grease point
3. Hour interval
15
3. Hour interval
Controls
Product Overview
Become familiar with all the controls before you start
the engine and operate the machine.
Control Panel
g019888
Figure 4
Side Discharge Machine
1. Height-of-cut deck lift
pedal
6. Roll bar
2. Transport lock
7. Seat belt
3. Parking-brake lever
8. Fuel cap
4. Controls
5. Motion-control lever
g010363
Figure 6
1. Hour meter
9. Mower deck
10. Caster wheel
6. Glow-plug light
2. Key switch
7. Engine-temperature light
3. Fuel-selector valve
4. Audible alarm
5. Glow-plug switch
8. Throttle control
9. PTO switch
Key Switch
The key switch, used to start and shut off the engine,
has 3 positions: OFF, RUN, and START . Refer to
Starting and Shutting Off the Engine (page 26).
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 6).
Safety-Interlock Indicators
There are symbols on the hour meter that indicate
with a black triangle that the interlock component is
positioned correctly (Figure 7).
g020466
Figure 5
Rear Discharge Machine
1. Z Stand©
6. Fuel cap (both sides)
2. Height-of-cut lever
7. Parking-brake lever
3. Motion-control lever
4. Seat belt
5. Roll bar
8. Mower deck
9. Caster wheel
16
Battery-Indicator Light
Audible Alarm
If you turn the key switch to the ON position for a
few seconds, the battery voltage displays in the area
where the hours are normally displayed.
This machine has an audible alarm that alerts the user
to shut off the engine; otherwise, engine damage can
occur from over heating. Refer to Operating with the
Overheat Sensor (page 34).
The battery light turns on when the ignition is turned
on and when the charge is below the correct operating
level (Figure 7).
Fuel-Selector Valve
The fuel-selector valve is located behind the seat.
Close the fuel-selector valve when transporting or
storing mower.
Move the selector valve to the left or right position for
operation.
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.
g009610
Figure 7
1. Safety-interlock symbols
3. Battery light
2. Hour meter
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.
Throttle Control
The throttle controls the engine speed, and it has a
continuous-variable setting from the SLOW to FAST
position (Figure 6).
Neutral-Lock Position
Use the NEUTRAL-LOCK position with the
safety-interlock system to engage and to determine
the NEUTRAL position.
Glow-Plug Light
The glow-plug indicator light turns on when the
glow-plug button is engaged (Figure 6).
Glow-Plug Switch
This switch activates the glow plugs and is indicated
by the glow-plug light. Hold down the glow-plug switch
for 10 seconds prior to starting the machine.
Temperature Light
The temperature light comes on when the engine is
over heating (Figure 6).
17
Operation
•
Note: Determine the left and right sides of the
machine from the normal operating position.
Before Operation
•
Before Operation Safety
•
General Safety
• Never allow children or untrained people to
•
•
•
•
•
•
•
operate or service the machine. Local regulations
may restrict the age of the operator. The owner
is responsible for training all operators and
mechanics.
Become familiar with the safe operation of the
equipment, operator controls, and safety signs.
Know how to stop the machine and shut off the
engine quickly.
Check that operator-presence controls, safety
switches, and shields are attached and functioning
properly. Do not operate the machine unless they
are functioning properly.
Before mowing, always inspect the machine to
ensure that the blades, blade bolts, and cutting
assemblies are in good working condition.
Replace worn or damaged blades and bolts in sets
to preserve balance.
Inspect the area where you will use the machine
and remove all objects that the machine could
throw.
Evaluate the terrain to determine the appropriate
equipment and any attachments or accessories
required to operate the machine properly and
safely.
•
•
•
Performing Daily
Maintenance
Before starting the machine each day, perform the
Each Use/Daily procedures listed in Maintenance
(page 40).
Adding Fuel
Fuel Safety
• To avoid personal injury or property damage, use
•
•
•
•
•
•
containers on the ground, away from your vehicle
before filling.
Remove the equipment from the truck or trailer
and refuel it while it is on the ground. If this is not
possible, then refuel from a portable container
rather than a fuel-dispenser nozzle.
Do not operate the machine without the entire
exhaust system in place and in proper working
condition.
Keep the fuel-dispenser 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.
If you spill fuel on your clothing, change your
clothing immediately. Wipe up any fuel that spills.
Never overfill the fuel tank. Replace the fuel cap
and tighten it securely.
Store fuel in an approved container and keep it
out of the reach of children. Never buy more than
a 30-day supply of fuel.
Do not fill the fuel tank completely full. Add fuel to
the fuel tank until the level is 6 to 13 mm (1/4 to
1/2 inch) below the bottom of the filler neck. This
empty space in the tank allows fuel to expand.
– Avoid prolonged breathing of vapors.
– Keep your face away from the nozzle and fuel
tank opening.
– Avoid contact with skin; wash off spills with
soap and water.
Recommended Fuel
extreme care in handling fuel. Fuel vapors are
flammable and explosive.
Extinguish all cigarettes, cigars, pipes, and other
sources of ignition.
Use only an approved fuel container.
Do not remove the fuel cap or add fuel to the fuel
tank while the engine is running or while hot.
Do not refuel the machine indoors.
Do not store the machine or fuel container where
there is an open flame, spark, or pilot light, such
as on a water heater or on other appliances.
Do not fill containers inside a vehicle or on a truck
or trailer bed with a plastic liner. Always place
The engine runs on clean, fresh diesel fuel with
a minimum octane 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).
18
Using summer-grade diesel fuel above -7°C
(20°F) contributes toward longer life of the pump
components.
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
ASTM D6751 or EN14214.
• The blended fuel composition should meet ASTM
D975 or EN590.
• Painted surfaces may be damaged by biodiesel
blends.
• Use B5 (biodiesel contend of 5%) or lesser blend
in cold weather.
• Monitor seals, hoses, gaskets in contact with fuel
as they may degrade over time.
• Fuel filter plugging may be expected for a time
after converting to biodiesel blends.
g027726
• Contact your distributor if you wish for more
Figure 8
information on biodiesel.
Filling the Fuel Tank
1.
Park the machine on level ground.
2.
Shut off the engine and engage the parking
brake.
3.
Clean around the fuel-tank cap.
4.
Fill the fuel tank to the bottom of the filler neck
(Figure 8).
Switching the Fuel Tanks
Important: Do not allow the machine to run out
of fuel, as this can damage the machine.
The fuel-selector valve is located behind the left side
of the seat.
The unit has 2 fuel tanks. One tank is on the left side
and one on the right side. Each tank connects to the
fuel-selector valve. From there a common fuel line
leads to the engine (Figure 9).
Note: Do not fill the fuel tank completely full.
The empty space in the tank allows the fuel to
expand.
To use the left fuel tank, rotate the fuel-selector
valve to the left. To use the right fuel tank, rotate the
fuel-selector valve to the right (Figure 9).
Close the fuel-selector valve before transporting or
storing machine.
19
Using the
Rollover-Protection System
(ROPS)
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.
g000962
• Do not wear the seat belt when the roll bar
is in the down position.
Figure 9
1. Left fuel tank
2. Fuel-selector valve
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance
permits.
Breaking in a New Machine
• Check carefully for overhead clearances
(i.e., branches, doorways, electrical wires)
before driving under any objects and do
not contact them.
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.
Lowering the Roll Bar
Important: Lower the roll bar only when
absolutely necessary.
1.
Remove the hairpin cotters and remove the 2
pins (Figure 11).
2.
Lower the roll bar to the down position (Figure
10).
Note: There are 2 down positions; refer to
Figure 10.
3.
20
Install the 2 pins and secure them with the
hairpin cotters (Figure 11).
Using the Safety-Interlock
System
WARNING
If 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.
g004954
Figure 10
1. Full-down position
Understanding the
Safety-Interlock System
2. Down position with the
bagger installed
The safety-interlock system is designed to prevent the
engine from starting unless:
• The parking brake is engaged.
• The blade-control switch (PTO) is disengaged.
• The motion-control levers are in the NEUTRAL-LOCK
position.
Important: Ensure that you secure the rear
part of the seat with the seat latch.
Raising the Roll Bar
Important: Always use the seat belt with the roll
bar in the raised position.
1. Remove the hairpin cotters and remove the 2
pins (Figure 11).
2. Raise the roll bar to the upright position, install
the 2 pins, and secure them with the hairpin
cotters (Figure 11).
The safety-interlock system also is designed to shut off
the engine when the traction controls are moved from
the locked position with the parking brake engaged or
if you rise from the seat when the PTO is engaged.
The hour meter has symbols to notify the user when
the interlock component is in the correct position.
When the component is in the correct position, a
triangle lights up in the corresponding square.
g009612
Figure 12
1. Triangles light up when the interlock components are in the
correct position
Testing the Safety-Interlock
System
g004955
Figure 11
1. Roll bar
2. Raised position
Service Interval: Before each use or daily
3. Pin
4. Hairpin cotter
Test the safety-interlock system before you use the
machine each time. If the safety system does not
21
Unlatching the Seat
operate as described below, have an Authorized
Service Dealer repair the safety system immediately.
1.
2.
Sitting 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.
Sitting 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.
Move the seat to the most rearward position.
Note: This prevents interference when you
raise the seat.
Sitting 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.
5.
1.
Sitting 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.
Push the seat latch rearward to unlatch the seat.
3.
Raise the seat up (Figure 14).
Note: This allows access to the machine under
the seat.
g000950
Figure 14
1. Seat latch
2. Fuel cap
Sitting 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.
3. Seat
Changing the Seat
Suspension
The seat is adjustable to provide a smooth and
comfortable ride. Position the seat where you are
most comfortable.
Positioning the Seat
To adjust it, turn the knob in front either direction to
provide the best comfort (Figure 15).
The seat moves forward and backward. Position the
seat where you have the best control of the machine
and are most comfortable.
To adjust, move the lever sideways to unlock the seat
(Figure 13).
g019768
Figure 15
g019754
Figure 13
1. Seat-suspension knob
22
During Operation
• Never run an engine in an area where exhaust
During Operation Safety
•
•
General Safety
• The owner/operator can prevent and is responsible
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
for accidents that may cause personal injury or
property damage.
Wear appropriate clothing, including eye
protection; long pants; slip-resistant, substantial
footwear; and hearing protection. Tie back long
hair and do not wear loose jewelry.
Use your full attention while operating the
machine. Do not engage in any activity that
causes distractions; otherwise, injury or property
damage may occur.
Do not operate the machine while ill, tired, or
under the influence of alcohol or drugs.
Never carry passengers on the machine and keep
bystanders and pets away from the machine
during operation.
Operate the machine only in good visibility to avoid
holes or hidden hazards.
Avoid mowing on wet grass. Reduced traction
could cause the machine to slide.
Ensure that all drives are in neutral, the parking
brake is engaged, and you are in the operating
position before you start the engine.
Keep your hands and feet away from the cutting
units. Keep clear of the discharge opening at all
times.
Look behind and down before backing up to be
sure of a clear path.
Use care when approaching blind corners, shrubs,
trees, or other objects that may obscure your
vision.
Do not mow near drop-offs, ditches, or
embankments. The machine could suddenly roll
over if a wheel goes over the edge or if the edge
gives way.
Stop the blades whenever you are not mowing.
Stop the machine, shut off the engine, remove
the key, and inspect the blades after striking an
object or if there is an abnormal vibration in the
machine. Make all necessary repairs before
resuming operation.
Slow down and use caution when making turns
and crossing roads and sidewalks with the
machine. Always yield the right-of-way.
Disengage the drive to the cutting unit, shut off the
engine, and remove the key before adjusting the
height of cut (unless you can adjust it from the
operating position).
•
•
•
•
•
gases are enclosed.
Never leave a running machine unattended.
Before leaving the operating position (including
to empty the catchers or to unclog the chute), do
the following:
– Stop the machine on level ground.
– Disengage the power takeoff and lower the
attachments.
– Engage the parking brake.
– Shut off the engine and remove the key.
– Wait for all moving parts to stop.
Do not operate the machine when there is the risk
of lightning.
Do not use the machine as a towing vehicle unless
it has a hitch installed.
Do not change the governor speed or overspeed
the engine.
Use only accessories and attachments approved
by Toro.
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.
g229846
Figure 16
1. Wear hearing protection.
Rollover Protection System
(ROPS) Safety
• Do not remove the roll bar from the machine.
• Ensure that the seat belt is attached and that you
•
•
•
•
can release it quickly in an emergency.
Always wear your seat belt when the roll bar is up.
Check carefully for overhead obstructions and do
not contact them.
Keep the roll bar in safe operating condition by
thoroughly inspecting it periodically for damage
and keeping all the mounting fasteners tight.
Replace a damaged roll bar. Do not repair or alter
it.
Slope Safety
• Slopes are a major factor related to loss of control
and rollover accidents, which can result in severe
23
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, do the following:
– 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.
g221745
Figure 17
1. Safe Zone—use the
machine here on slopes
less than 15 degrees or
flat areas.
2. Danger Zone—use a
walk-behind mower and/or
a hand trimmer on slopes
greater than 15 degrees
and near drop-offs or
water.
3. Water
• 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
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.
• Avoid starting, stopping, or turning the machine on
slopes. Avoid making sudden changes in speed or
direction; turn slowly and gradually.
• 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
counterweights.
• 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.
24
4. W=width of the machine
5. Keep a safe distance
(twice the width of the
machine) between the
machine and any hazard.
Engaging the Blade-Control
Switch (PTO)
Operating the Parking
Brake
Note: Engaging the blade-control switch (PTO) with
the throttle position at half or less causes excessive
wear to the drive belts.
Always engage the parking brake when you stop the
machine or leave it unattended.
Engaging the Parking Brake
Park the machine on a level surface.
g008945
Figure 20
Disengaging the Blade-Control
Switch (PTO)
g187227
Figure 18
Disengaging the Parking Brake
g009174
Figure 21
Operating the Throttle
You can move the throttle control between the FAST
and SLOW positions (Figure 22).
Always use the FAST position when turning on the
mower deck with the blade-control switch (PTO).
g187226
Figure 19
Operating the Mower
Blade-Control Switch (PTO)
g008946
Figure 22
The blade-control switch (PTO) starts and stops the
mower blades and any powered attachments.
25
Starting the Engine in Cold
Weather (Below 23°F or -5°C)
Starting and Shutting Off
the Engine
Use the correct engine oil for the starting temperature;
refer to Engine-Oil Specifications (page 47).
Starting the Engine in Normal
Weather
Important: Use starting cycles of no more than
30 seconds per minute to avoid overheating the
starter motor.
Important: Use starting cycles of no more than
30 seconds per minute to avoid overheating the
starter motor.
Note: Do not use fuel left over from the summer. Use
only fresh winter-grade diesel fuel.
Note: Additional starting cycles may be required
when starting the engine for the first time after the fuel
system has been completely without fuel.
g032594
Figure 24
g032593
Figure 23
26
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 26
1. Motion-control
lever—NEUTRAL-LOCK
position
4. Backward
2. Center, unlocked position
5. Front of machine
3. Forward
Driving the Machine
g032595
Figure 25
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.
Important: Make sure that you close the
fuel-shutoff valve before transporting or storing
the machine, as fuel leakage may occur. Engage
the parking brake before transporting the
machine. Make sure that you remove the key as
the fuel pump may run and cause the battery to
lose charge.
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.
27
Driving Backward
WARNING
The machine can spin very rapidly. You
may lose control of the machine and cause
personal injury or damage to the machine.
1.
Move the levers to the center, unlocked position.
2.
To go backward, slowly pull the motion-control
levers rearward (Figure 28).
• Use caution when making turns.
• Slow the machine down before making
sharp turns.
Driving Forward
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 25).
2.
Move the levers to the center, unlocked position.
3.
To go forward, slowly push the motion-control
levers forward (Figure 27).
g008953
Figure 28
g008952
Figure 27
28
Using the Side Discharge
Adjusting the Height of Cut
Machines with Side Discharge
Only
Using the Transport Lock
The mower has a hinged grass deflector that
disperses clippings to the side and down toward the
turf.
The transport lock has 2 positions, and is used with
the deck-lift pedal. There is a LOCK position and
an UNLOCK position for the transport position of the
mower deck (Figure 29).
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.
• 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.
• 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.
g229103
Figure 29
Transport-Lock Positions
1. Transport lock knob
2. LOCK position—The
mower deck locks into the
transport position.
29
3. UNLOCK position—The
mower deck does not lock
into the transport position.
Adjusting the Height-of-Cut Pin
Adjusting the Anti-Scalp
Rollers
The height-of-cut is adjusted from 25 to 140 mm (1
to 5-1/2 inches) in 6 mm (1/4 inch) increments by
relocating the clevis pin into different hole locations.
1.
Move the transport lock to the lock position.
2.
Push on the deck-lift pedal with your foot, and
raise the mower deck to the transport position
(also the 140 mm (5-1/2 inch) cutting height
position) as shown in Figure 30.
3.
To adjust, rotate the pin 90 degrees and remove
the pin from the height-of-cut bracket (Figure
30).
4.
Select a hole in the height-of-cut bracket
corresponding to the height-of-cut desired, and
insert the pin (Figure 30).
5.
Push on the deck lift, pull back on the transport
lock, and slowly lower the mower deck.
For Machines with Side Discharge
Whenever you change the height-of-cut, adjust the
height of the anti-scalp rollers.
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.
Adjust the anti-scalp rollers as shown in Figure
31, Figure 32, and Figure 33.
g029955
Figure 31
1. Anti-scalp roller
4. Flange nut
2. Spacer
5. Bolt
3. Bushing
g027343
Figure 30
1. Deck-lift pedal
3. Transport lock
2. Cut-of-height pin
g029956
Figure 32
30
1. Anti-scalp roller
3. Flange nut
2. Bushing
4. Bolt
g029957
Figure 33
1. Anti-scalp roller
4. Flange nut
2. Spacer
5. Bolt
3. Bushing
g024242
Figure 34
Adjusting the Anti-Scalp
Rollers
1. Flange nut
3. Bushing
2. Anti-scalp roller
4. Bolt
For Machines with Rear Discharge
Whenever you change the height of cut, it is
recommended to adjust the height of the anti-scalp
rollers.
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.
Adjust the anti-scalp rollers as shown in Figure
34 and Figure 35.
g024243
Figure 35
31
1. Bolt
3. Anti-scalp roller
2. Bushing
4. Flange nut
Adjusting the Flow Baffle
Cam Locks
Adjusting the Skid(s)
For Machines with Rear Discharge
For Machines with Side Discharge
Mount the skids in the lower position when operating
in height of cuts higher than 64 mm (2-1/2 inches) and
in the higher position when operating in height of cuts
lower than 64 mm (2-1/2 inches).
This procedure is applicable only to machines with the
flow-baffle locks. Certain models have nuts and bolts
in place of the flow-baffle locks and can be adjusted
the same.
Note: When the skids become worn, switch the skid
to the opposite sides of the mower, flipping them
over. This allows you to use the skids longer before
replacing them.
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
3.
You can adjust the mower-discharge flow for different
types of mowing conditions. Position the cam locks
and baffle to give the best quality of cut.
1.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
2.
Remove the carriage bolts and nuts from each
skid (Figure 36).
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
3.
To adjust the cam locks, swing the lever up to
loosen the cam lock (Figure 37).
4.
Adjust the baffle and cam locks in the slots to
the desired discharge flow.
5.
Swing the lever back over to tighten the baffle
and cam locks (Figure 37).
6.
If the cam locks do not lock the baffle into place
or it is too tight, loosen the lever and then rotate
the cam lock.
Note: Adjust the cam lock until the desired
locking pressure is achieved.
g024244
Figure 36
1. Carriage bolt
3. Nut
2. Skid
4.
Move each skid to the desired position and
secure them with the carriage bolts and nuts.
Note: Only use the top or center sets of holes
to adjust the skids. The bottom holes are used
when switching sides on the mower deck, at
which time they become the top holes on the
other side of the mower.
5.
g027727
Figure 37
To prevent damaging the skid, torque the
carriage bolts and nuts for each skid to 12.4 to
14.7 N∙m (110 to 130 in-lb).
32
Positioning the Flow Baffle
Position C
For Machines with Side Discharge
This is the full open position. The suggested use for
this position is as follows:
The following figures are only recommendations
for use. Adjustments vary by grass type, moisture
content, and the height of the grass.
• Tall, dense grass mowing conditions
• Wet conditions
Note: If the engine power draws down and the
• Lowers the engine-power consumption
mower ground speed is the same, open up the baffle.
• Allows increased ground speed in heavy conditions
Position A
This is the full 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
g005834
Figure 40
g005832
Figure 38
Position B
Use this position when bagging. Always align it with
the blower opening.
g005833
Figure 39
33
Operating with the Overheat
Sensor
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.
This machine has a sensor that turns off the mower
deck when the engine overheats. When the engine
overheats, the audible alarm and light alarm turns on
along with the mower deck turning off.
Using a Slower Cutting Speed
If the mower deck turns off automatically because of
overheating, you will be able to drive the machine to
a safe area or to a truck or trailer.
To improve cut quality, use a slower ground speed
in certain conditions.
If the machine overheats, ensure that the area around
the engine and radiator is clear of any debris. Shut off
the engine and allow it to cool before you engage the
mower deck. If the engine continues to overheat, take
your machine to an Authorized Service Dealer.
Avoiding Cutting Too Low
When mowing uneven turf, raise the cutting height
to avoid scalping the turf.
Stopping the Machine
Operating Tips
If you must stop the forward motion of the machine
while mowing, a clump of grass clippings may
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
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.
Maintaining the Blade(s)
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
34
Pushing the Machine by
Hand
After Operation
After Operation Safety
Important: Always push the machine by hand.
Never tow the machine because hydraulic damage
may occur.
General Safety
• Clean grass and debris from the cutting units,
Pushing the Machine
mufflers, and engine compartment to help prevent
fires. Clean up oil or fuel spills.
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 bypass valves counterclockwise 1
turn to push (Figure 42).
• Shut off the fuel and remove the key before storing
or transporting the machine.
• Disengage the drive to the attachment whenever
you are transporting or not using the machine.
• Allow the engine to cool before storing the machine
in any enclosure.
• Never store the machine or fuel container where
Note: This allows hydraulic fluid to bypass the
there is an open flame, spark, or pilot light, such
as on a water heater or on other appliances.
pump enabling the wheels to turn.
Important: Do not rotate bypass valves
more than 1 turn. This prevents valves from
coming out of the body and causing fluid to
run out.
Using the Fuel-Shutoff
Valve
4.
The fuel-shutoff valve is located under the seat. Move
the seat forward to access it.
Close the fuel-shutoff valve for transport, maintenance,
and storage.
Ensure that the fuel-shutoff valve is open when
starting the engine.
g008948
Figure 41
1. ON position
2. OFF position
35
Disengage the parking brake before pushing.
Selecting a Trailer
Changing to Machine Operation
Rotate the bypass valves clockwise 1 turn to operate
machine (Figure 42).
WARNING
Loading a machine onto a trailer or truck
increases the possibility of tip-over and could
cause serious injury or death (Figure 43).
Note: Do not over-tighten the bypass valves.
Important: The machine does not drive unless
bypass valves are turned in.
• Use only a full-width ramp; do not use
individual ramps for each side of the
machine.
• Do not exceed a 15-degree angle between
the ramp and the ground or between the
ramp and the trailer or truck.
• Ensure that the length of the ramp is at
least 4 times as long as the height of the
trailer or truck bed to the ground. This
ensures that the ramp angle does not
exceed 15 degrees on flat ground.
g010371
Figure 42
1. Side console controls
3. Hydraulic pumps
2. Bypass valve
Transporting the Machine
Use a heavy-duty trailer or truck to transport the
machine. Use a full-width ramp. Ensure that the trailer
or truck has all the necessary brakes, lighting, and
marking as required by law. Please carefully read all
the safety instructions. Knowing this information could
help you or bystanders avoid injury. Refer to your
local ordinances for trailer and tie-down requirements.
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 drive the machine on a public street
or roadway.
36
1.
If using a trailer, connect it to the towing vehicle
and connect the safety chains.
2.
If applicable, connect the trailer brakes and
lights.
3.
Lower the ramp, ensuring that the angle
between the ramp and the ground does not
exceed 15 degrees (Figure 43).
4.
Back the machine up the ramp (Figure 44).
g028043
Figure 44
1. Back the machine up the
ramp.
2. Drive the machine forward
down the ramp.
5.
Shut off the engine, remove the key, and engage
the parking brake.
6.
Tie down the machine near the front caster
wheels and the rear bumper with straps, chains,
cable, or ropes (Figure 45). Refer to local
regulations for tie-down requirements.
g027996
Figure 43
1. Full-width ramp in stowed
position
4. Ramp is at least 4 times
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
Loading the Machine
WARNING
g028622
Figure 45
Loading a machine onto a trailer or truck
increases the possibility of tip-over and could
cause serious injury or death.
1. Tie-down loops
• Use extreme caution when operating a
machine on a ramp.
Unloading the Machine
• Back the machine up the ramp and drive it
forward down the ramp.
• 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.
37
1.
Lower the ramp, ensuring that the angle
between the ramp and the ground does not
exceed 15 degrees (Figure 43).
2.
Drive the machine forward down the ramp
(Figure 44).
Using the Z StandTM
4.
The Z Stand raises the front end of the machine to
allow you to clean the mower and remove the blades.
Swing the stand foot out front and slide it
toward machine, into the bottom of slot (Figure
46 and Figure 47).
WARNING
The machine could fall onto someone and
cause serious injury or death.
• Use extreme caution when operating the
machine on the Z Stand.
• Use the Z Stand only for cleaning the
mower and removing the blades.
g001812
Figure 47
1. Z Stand (positioned in slot) 3. Latch resting on pivot tab
• Do not keep the machine on the Z Stand
for extended periods of time.
2. Crack in side walk or turf
• Always shut off the engine, set the
parking brake, and remove the key before
performing any maintenance to the mower.
5.
Set the foot of the stand on the ground and rest
the latch on the pivot tab (Figure 47).
6.
Start the engine and put it at half throttle.
Driving up onto the Z Stand
Note: For best results, place the foot of the
stand into the seams in sidewalks or into the turf
(Figure 47).
Important: Use the Z Stand on a level surface.
1.
Raise the mower deck to the transport position.
2.
Remove the bracket pin (Figure 46).
7.
Drive the machine onto the stand. Stop when
the latch drops over the tab into the locked
position (Figure 47).
8.
Engage the parking brake and turn off the
engine.
9.
Chock or block the drive wheels.
WARNING
The parking brake may not hold the
machine parked on the Z Stand and
could cause personal injury or property
damage.
g001811
Figure 46
1. Z Stand
2. Bracket pin
Do not park on the Z Stand unless the
wheels are chocked or blocked.
4. Bottom of slot
5. Latch
10.
3. Bracket
3.
Raise the latch.
38
Perform the maintenance.
Driving off the Z Stand
1.
Remove the chocks or blocks.
2.
Raise the latch to the unlocked position (Figure
48).
g001813
Figure 48
1. Z Stand
3. Locked position
2. Latch
4. Unlocked position
3.
Start the engine and place it at half throttle.
Disengage the parking brake.
4.
Slowly drive backward off the stand.
5.
Return the stand to its rest position (Figure 46).
39
Maintenance
Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 8 hours
• Check the engine cooling system level.
• Check the hydraulic fluid.
After the first 25 hours
• Change the hydraulic filter.
After the first 50 hours
• Replace the engine oil.
• Change the engine-oil filter.
• Change the engine oil.
After the first 100 hours
• Check the wheel-hub slotted nut.
• Change the gearbox oil.
Before each use or daily
•
•
•
•
•
•
Check the safety system.
Check the engine-oil level.
Check the engine cooling system level.
Clean the engine-oil cooler.
Inspect the blades.
Clean the mower deck.
Every 25 hours
•
•
•
•
•
•
Grease the mower deck and spindles.
Grease the mower belt idler arm.
Grease the pump belt idler arm.
Grease the PTO-drive belt idler arm.
Grease the brake lever.
Check the hydraulic fluid.
Every 40 hours
• Drain the water separator.
Every 50 hours
•
•
•
•
Check
Check
Check
Check
Every 100 hours
•
•
•
•
•
•
•
Lubricate the deck-lift pivots.
Replace the engine oil.
Change the engine oil.
Check the gearbox-oil level.
Check the engine cooling system hoses.
Inspect the belts for cracks and wear.
Check the hydraulic hoses.
Every 150 hours
• Add light oil or spray lubrication to the machine; refer to lubrication.
Every 200 hours
• Change the engine-oil filter.
• Grease the brake pivot.
Every 250 hours
• Check and/or replace the air filter (more often in dirty or dusty conditions).
• Change the hydraulic filter and hydraulic fluid when using Mobil® 1 fluid.
Every 400 hours
• Replace the fuel filter (more often in dirty or dusty conditions).
the
the
the
the
tire pressure
PTO-drive belt.
pump drive belt.
alternator belt.
40
Maintenance Service
Interval
Every 500 hours
Yearly
Maintenance Procedure
•
•
•
•
Check the wheel-hub slotted nut.
Adjust the caster-pivot bearing.
Adjust the electric clutch.
Change the hydraulic filter and hydraulic fluid when using Toro® HYPR-OIL™ 500
hydraulic fluid.
•
•
•
•
Grease the front caster pivots (more often in dirty or dusty conditions).
Lubricate the caster-wheel hubs.
Change the gearbox oil.
Change the engine coolant.
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.
Remove the key from the switch before you perform any maintenance.
Pre-Maintenance
Procedures
blade-attachment bolts. Replace all worn or
damaged decals.
• Never interfere with the intended function of a
safety device or reduce the protection provided
by a safety device. Check their proper operation
regularly.
Maintenance Safety
• Before repairing the machine do the following:
•
•
•
•
•
•
•
•
•
•
• Check the parking brake operation frequently.
– Disengage the drives.
– Engage the parking brake.
– Shut off the engine and remove the key.
Park the machine on a level surface.
Clean grass and debris from the cutting unit,
drives, mufflers, and engine to help prevent fires.
Clean up oil or fuel spills.
Do not allow untrained personnel to service the
machine.
Use jack stands to support the machine and/or
components when required.
Carefully release pressure from components with
stored energy.
Disconnect the battery before making any repairs.
Disconnect the negative terminal first and the
positive terminal last. Connect the positive
terminal first and negative last.
Use care when checking the blades. Wrap the
blade(s) or wear thickly padded gloves, and use
caution when servicing them. Only replace blades;
do not straighten or weld them.
Keep your hands and feet away from moving
parts. If possible, do not make adjustments with
the engine running.
Keep all parts in good working condition
and all hardware tightened, especially the
Adjust and service as required.
41
Lubrication
Releasing the Mower-Deck
Curtain
Greasing the Machine
Loosen the bottom bolt of the curtain to release
the mower-deck curtain and get access to the top
of the mower deck (Figure 49). After performing
maintenance, install the curtain and tighten the bolt.
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.
Note: Make sure that you scrape any paint off
the front of the fitting(s).
g027945
Figure 49
1. Bolt
2. Curtain
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.
Greasing the Front Caster
Pivots
Removing the Sheet-Metal
Guard
Service Interval: Yearly (more often in dirty or dusty
conditions).
Loosen the 2 front bolts and remove the sheet-metal
guard to access the mower belts and spindles
(Figure 50). After performing maintenance, install the
sheet-metal guard and tighten the bolts.
1.
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 56).
2.
Remove the hex plug.
3.
Thread a grease fitting into the hole.
4.
Pump grease into the fitting until it oozes out
around the top bearing.
5.
Remove the grease fitting from the hole. Install
the hex plug and cap.
Adding Grease
Lubricate the grease fittings as shown on the Check
Service Reference Aid decal (Figure 51 or Figure 52).
g027946
Figure 50
1. Sheet-metal guard
2. Bolt
42
Adding Light Oil or Spray
Lubrication
Side Discharge Machines
Service Interval: Every 100 hours
Lubricate the deck-lift pivots.
decal136-5510
Figure 51
Side Discharge Machines
g017028
Figure 53
Adding Light Oil or Spray
Lubrication
Rear Discharge Machines
Service Interval: Every 150 hours
Lubricate the machine in the following areas with
spray type lubricant or light oil.
• Seat-switch actuator
• Brake-handle pivot
• Brake-rod bushings
• Motion control bronze bushings
decal136-5519
Figure 52
Rear Discharge Machines
43
Greasing the Mower Deck
and Belt Idlers
Service Interval: Every 25 hours—Grease the mower
deck and spindles.
Grease with No. 2 lithium or molybdenum grease.
Important: Make sure that the cutting-unit
spindles are full of grease weekly.
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 bottom bolt holding the mower-deck
curtain to the mower deck; refer to Releasing
the Mower-Deck Curtain (page 42).
4.
Remove the sheet-metal guard; refer to
Removing the Sheet-Metal Guard (page 42)
5.
Remove the belt covers.
6.
Grease the idler arm on the mower deck (Figure
54).
7.
Grease the fittings on the push arms (Figure 54
or Figure 55).
g194085
Figure 55
Rear Discharge Machines
8.
Grease the PTO-drive belt idler arm (Figure 56).
9.
Grease the pump belt idler arm (Figure 56).
g007170
Figure 56
g187362
Figure 54
Side Discharge Machines
44
10.
Install the sheet-metal guard.
11.
Tighten the bottom bolt holding the mower-deck
curtain to the mower deck.
Lubricating the
Caster-Wheel Hubs
12.
Insert the assembled nut and axle into the wheel
on the side of the wheel with the new seal and
bearing.
Service Interval: Yearly
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 adhesive 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, then torque to 2 to 3 N∙m (20 to 25 in-lb).
1.
2.
Park the machine on a level surface, disengage
the blade-control switch, 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.
Note: Make sure that the axle does not extend
beyond either nut.
Figure 57
2. Spacer nut with wrench
flats
3.
Raise the mower for access.
4.
Remove the caster wheel from the caster forks.
5.
Remove the seal guards from the wheel hub.
6.
Remove a spacer nut from the axle assembly in
the caster wheel.
Note: Thread-locking adhesive has been
applied to lock the spacer nuts to the axle.
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.
Note: Replace the seals.
11.
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 adhesive.
g006115
1. Seal guard
17.
If the axle assembly is missing both spacer nuts,
apply a thread-locking adhesive 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.
45
Engine Maintenance
Engine Safety
• Shut off the engine and remove the key before
checking the oil or adding oil to the crankcase.
• Keep your hands, feet, face, clothing, and other
body parts away the muffler and other hot surfaces.
Servicing the Air Cleaner
Note: Check the filters more frequently if operating
conditions are extremely dusty or sandy.
Removing the Air Filter
Service Interval: Every 250 hours (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.
Release the latches on the air cleaner and pull
the air-cleaner cover off the air-cleaner body
(Figure 58).
4.
Clean the inside of the air-cleaner cover with
compressed air.
5.
6.
g001049
Figure 58
1. Air-filter body
3. Air-cleaner cover
2. Air filter
4. Latches
Installing the Air Filter
1.
If installing a new filter, check the filter for
shipping damage. Do not use a damaged filter.
2.
Note: Avoid knocking the filter into the side of
Carefully slide the filter into the filter body
(Figure 59).
the body.
Note: Ensure that it is fully seated by pushing
Inspect the filter for damage by looking into the
filter while shining a bright light on the outside
of the filter.
on the outer rim of the filter while installing it.
Gently slide the filter out of the air-cleaner body
(Figure 58).
Important: Do not press on the soft inside
area of the filter.
Note: Holes in the filter appear as bright spots.
3.
If the filter is damaged, discard it.
46
Install the air-cleaner cover and secure the
latches (Figure 59).
g001061
Figure 60
Preparing to Service the Engine
Oil
Important: The fasteners for the front engine
panel are designed to remain on the machine after
cover removal. Loosen all of the fasteners a few
turns so that the panel is loose but still attached,
then go back and loosen them until the panel
comes free. This prevents you from accidentally
stripping the bolts free of the retainers.
g001048
Figure 59
1. Air-filter body
3. Air-cleaner cover
2. Air filter
4. Latches
Tilt the seat forward, loosen the bolts holding the front
engine panel and remove it (Figure 61).
Servicing the Engine Oil
Engine-Oil Specifications
Oil Type: High-quality detergent oil classified API
Service CJ-4 or higher for diesel engines. Do not use
special additives with recommended oils.
Crankcase Capacity: 3.7 L (3.9 US qt)
Viscosity: See the table below.
g012347
Figure 61
1. Bolt
2. Front engine panel
Note: After servicing the engine oil, install the engine
panel and tilt the seat into its upright position.
47
Checking the Engine-Oil Level
Important: Add the oil very slowly and
do not block the opening of the filler hole
(Figure 40). If you add oil too fast or block
the hole, the oil could back up and foul the
air intakes, causing engine damage.
Service Interval: Before each use or daily
Note: Check the oil when the engine is cold.
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 the engine-oil level (Figure 62).
g000955
Figure 63
1. Note the clearance left in the filler opening.
Draining the Engine Oil
g032601
Service Interval: After the first 50 hours
Every 100 hours
1.
Start the engine and let it run for 5 minutes.
Note: This warms the oil so it drains better.
g032641
Figure 62
4.
Start the engine, run it at idle for 5 minutes,
shut off the engine, wait for 3 minutes, and then
check the engine-oil level. If needed, add oil up
to the FULL mark on the dipstick.
Important: Be sure to keep the engine-oil
level between the upper and lower limits on
the oil gauge. Engine failure may occur as
a result.
48
2.
Park the machine on a level surface, 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.
Changing the Engine-Oil Filter
Service Interval: After the first 50 hours
Every 200 hours
1.
Drain the oil from the engine; refer to Draining
the Engine Oil (page 48).
2.
Change the engine-oil filter (Figure 65).
g032646
g032649
g032642
Figure 64
Note: Dispose of the used oil at a recycling
center.
g032644
Figure 65
3.
49
Add oil; refer to Changing the Engine Oil (page
50).
Changing the Engine Oil
Adding Engine Oil
1.
Service Interval: After the first 50 hours
Every 100 hours
1.
Tilt the seat forward and remove the front engine
panel (Figure 67).
Start the engine and let it run for 5 minutes.
Note: This warms the oil so it drains better.
2.
Park the machine on a level surface.
3.
Disengage the blade-control switch (PTO), move
the motion-control levers to the NEUTRAL-LOCK
position, and engage the parking brake.
4.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
5.
Place a pan below the oil drain. Remove the
drain plug and let the oil drain completely (Figure
66).
6.
Remove the oil filler cap from the top of the
engine (Figure 68).
Note: This helps the oil to drain.
7.
g001312
Figure 67
Install the drain plug and tighten it to 35 N∙m
(25-1/2 ft-lb).
1. Knob
2. Front engine panel
Note: Dispose of the used oil at a recycling
center.
2.
Remove the oil-fill cap and dipstick (Figure 68).
g001162
Figure 68
1. Engine
2. Oil-fill cap
g001058
Figure 66
1. Back of the machine
3.
Use a hose and funnel to add oil to the engine
(Figure 69).
4.
Add oil slowly, checking the level frequently with
the dipstick until the level reaches the upper
hole on the dipstick. For the correct oil type
and viscosity to use in different temperature
conditions, refer to Servicing the Engine Oil
(page 47).
2. Drain plug
50
Fuel System
Maintenance
WARNING
Fuel-system components are under high
pressure. The use of improper components
can result in system failure, fuel leakage, and
possible explosion.
Use only approved fuel lines and fuel filters.
Servicing the Fuel Filter
and Water Seperator
g001163
Figure 69
1. Engine oil
Service Interval: Every 40 hours—Drain the water
separator.
2. Funnel and hose
Every 400 hours/Yearly (whichever comes
first)—Replace the fuel filter (more often in dirty
or dusty conditions).
Important: Add the oil very slowly and
do not block the opening of the filler hole
(Figure 70). If you add oil too fast or block
the hole, the oil could back up and foul the
air intakes, causing engine damage.
Draining the Water Separator
g000955
Figure 70
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.
Locate the water separator at the back left of
the machine.
4.
Place a drain pan below the water separator.
5.
Open the drain valve on the water separator
approximately 1 turn to allow water and other
contaminates to drain (Figure 71).
6.
Close the drain valve when only diesel fuel
comes out (Figure 71).
1. Note the clearance left in the filler opening.
5.
Replace the dipstick and install the front engine
panel.
6.
Start the engine and run it at idle for 5 minutes.
7.
Shut off the engine.
8.
Wait 3 minutes and check the oil level.
9.
Add oil, if required, to bring the level to the upper
hole on the dipstick.
10.
Replace the dipstick, filler cap, and the front
engine panel.
11.
Check for leaks.
Important: Do not overfill the crankcase
with oil because this may cause engine
damage.
51
g007169
Figure 71
1. Drain valve
2. Water separator
3. Back of machine
Changing the Fuel Filter
Never install a dirty fuel filter if it is removed from the
fuel line.
1.
Allow the machine to cool down.
2.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
3.
g007697
Figure 72
1. Fuel filter
2. Hose clamp
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
4. Left side of machine
5. Fuel-shutoff valve
3. Fuel pump
4.
Close the fuel shut-off valve (Figure 72).
5.
Loosen the 2 hose clamps and disconnect the
fuel lines from the fuel filter (Figure 72).
Servicing the Fuel Tank
6.
Install a new filter. Connect the fuel lines to the
fuel filter and install the 2 hose clamps (Figure
72).
Do not attempt to drain the fuel tank. Ensure that an
Authorized Service Dealer drains the fuel tank and
services any components of the fuel system.
7.
Open the fuel shut-off valve.
8.
Start the engine and check for leaks.
52
Electrical System
Maintenance
3.
Unlatch the seat and tilt the seat up.
4.
Remove the battery as shown in Figure 73.
Electrical System Safety
• 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.
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
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 73
WARNING
Incorrectly removing the cables from battery
could damage the machine and cables,
causing sparks. Sparks can cause the battery
gasses to explode, resulting in personal
injury.
• Always disconnect the negative (black)
battery cable before disconnecting the
positive (red) cable.
• Always connect the positive (red) battery
cable before connecting the negative
(black) cable.
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.
53
Installing the Battery
Note: Position the battery in the tray with the terminal
posts opposite from the hydraulic tank.
g000960
Figure 75
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.
1.
Unlatch the engine hood and raise the engine
hood to gain access to fuse holder (Figure 76).
2.
To replace the fuses, pull out on the fuse to
remove it.
3.
Install a new fuse (Figure 76).
g032751
Figure 74
Charging the 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.
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 75).
3.
Install the battery in the machine and connect
the battery cables, refer to Installing the Battery
(page 54).
Note: Do not run the machine with the battery
disconnected, electrical damage may occur.
g012492
Figure 76
54
1. Ignition—30 A (F1)
3. Clutch—10 A (F3)
2. Radiator fan—50 A (large,
heavy duty fuse)
4. Left fuel tank
Drive System
Maintenance
Adjusting the Tracking
The machine has a knob for adjusting the tracking
located under the seat.
Important: Adjust the handle neutral and
hydraulic pump neutral before adjusting the
tracking; refer to Adjusting the Control Handle
Neutral Position (page 65) and Setting the
Hydraulic Pump Neutral Position (page 69).
1.
Push both control levers forward the same
distance.
2.
Check if the machine pulls to 1 side. If it does,
shut off the machine and engage the parking
brake.
3.
Unlatch the seat and tilt the seat forward to
access the tracking knob.
Note: Determine the left and right sides of the
g001070
machine from the normal operating position.
4.
Figure 77
To make the machine go right, turn the knob
toward the right of the machine; refer to Figure
77.
5.
To make the machine go left, turn the knob
toward the left of the machine; refer to Figure 77.
6.
Repeat adjustment until the tracking is correct.
1. Tracking knob
4. Turn this way to track right.
2. Hydraulic tank
5. Turn this way to track left.
3. Hydraulic pumps
Checking the Tire Pressure
Service Interval: Every 50 hours/Monthly (whichever
comes first)
Maintain the air pressure in the rear tires at 90 kPa
(13 psi). Uneven tire pressure can cause uneven cut.
Check the tires when they are cold to get the most
accurate pressure reading.
Note: The front tires are semi-pneumatic tires and do
not require air pressure maintenance.
g001055
Figure 78
55
Checking the Wheel-Hub
Slotted Nut
Service Interval: After the first 100 hours—Check the
wheel-hub slotted nut.
Every 500 hours—Check the wheel-hub slotted
nut.
Torque the slottled nut to 286 to 352 N∙m (211 to 260
ft-lb).
Note: Do not use anti-seize compound on the wheel
hub.
Adjusting the Caster-Pivot
Bearing
g001297
Figure 79
Service Interval: Every 500 hours/Yearly (whichever
comes first)
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 from caster and tighten
the locknut (Figure 79).
4.
1. Spring washers
2. Locknut
Servicing the Gearbox
Checking the Gearbox-Oil Level
Service Interval: Every 100 hours
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 79).
Use SAE 75W-90 synthetic gear lube.
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 side or rear plug on the gearbox
(Figure 80).
4.
The oil should be up to the opening of the
gearbox.
5.
Add oil if needed to bring it to the correct level.
Important: Make sure that the spring
washers are installed correctly as shown in
Figure 79.
5.
3. Dust cap
Install the dust cap (Figure 79).
56
Adjusting the Electric
Clutch
Service Interval: Every 500 hours
The clutch is adjustable to ensure proper engagement
and proper braking.
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.
Unlatch the seat and tip it forward.
4.
Loosen the front engine panel knobs and
remove the panel.
5.
Pull up on the spring-loaded idler pulley for the
PTO-drive belt and remove the belt from the
clutch pulley (Figure 81).
g001156
Figure 80
1. Gearbox
3. Pulley
2. Side plug
4. Rear plug
Changing the Gearbox Oil
Service Interval: After the first 100 hours
Yearly
Contact an Authorized Service Dealer to change the
gearbox oil.
g007167
Figure 81
57
1. Spring-loaded idler pulley
3. PTO-drive belt
2. Clutch
4. Gearbox
6.
Unplug the electric connection for the clutch
(Figure 82).
7.
Remove the 2 bolts holding the rubber clutch
strap to the mower frame (Figure 82).
8.
Remove the center bolt holding the clutch to
the engine shaft and remove the clutch and key
(Figure 82).
g007166
Figure 82
1. Clutch
2. 2 bolts and nuts for clutch
strap
4. Clutch center bolt
5. Electrical connection
3. Rubber clutch strap
9.
Insert a 0.381 to 0.533 mm (0.015 to 0.021 inch)
feeler gauge through an inspection slot in the
side of the assembly (Figure 83).
Note: Make sure that it is between the armature
and the rotor friction surfaces.
10.
Tighten the locknuts until there is slight binding
on the feeler gauge but it can be moved easily
within the air gap (Figure 83).
11.
Repeat this for the remaining slots.
12.
Check each slot again and make slight
adjustments until the feeler gauge between
the rotor and armature has very slight contact
between them.
g007168
Figure 83
1. Slot
3. Feeler gauge
2. Adjusting nut
13.
Install the clutch to the engine shaft with the key.
14.
Apply thread-locking adhesive to the center bolt.
15.
While holding the crank shaft at the back of the
machine, install the center bolt and torque it to
68 N∙m (50 ft-lb) (Figure 82).
58
16.
Install the rubber clutch strap to the mower
frame with the 2 previously removed bolts and
nuts (Figure 82).
17.
Pull up on the spring-loaded idler for the
PTO-drive belt and install it onto the clutch
pulley (Figure 81).
18.
Plug in the electric connection for the clutch
(Figure 82).
19.
Install the front engine panel and tighten the
knobs.
20.
Lower down the seat.
Cooling System
Maintenance
Note: Do not open the radiator cap. Doing this may
induce air into the cooling system.
Servicing the Cooling
System
DANGER
Discharge of hot pressurized coolant or
touching hot radiator and surrounding parts
can cause severe burns.
• Do not remove the radiator cap when the
engine is hot. Always allow the engine to
cool at least 15 minutes or until the radiator
cap is cool enough to touch without
burning your hand before removing the
radiator cap.
1.
Position the machine on a level surface, shut off
the engine, and engage the parking brake.
2.
Unlatch the seat and tilt the seat up.
3.
With the engine cool, check the overflow bottle
level. The fluid needs to be up to the bump on
the outside of the overflow bottle (Figure 84).
4.
If the coolant level is low, add a 50/50 mix of
extended life antifreeze/Dex-Cool® and water to
the overflow bottle (Figure 84).
5.
Add the 50/50 coolant mix to the overflow bottle
and fill it to the indicator line on the bottle (Figure
84).
• Do not touch the radiator and surrounding
parts that are hot.
DANGER
The rotating shaft and fan can cause personal
injury.
• Do not operate the machine without the
covers in place.
• Keep your fingers, hands, and clothing
clear of rotating fan and driveshaft.
• Shut off the engine and remove the ignition
key before performing maintenance.
g001103
Figure 84
1. Antifreeze overflow bottle
CAUTION
Swallowing engine coolant can cause
poisoning.
• Do not swallow engine coolant.
• Keep out of reach from children and pets.
Checking the Radiator Coolant
Service Interval: Before each use or daily
After the first 8 hours
Every 100 hours
Fluid Type: 50/50 mix of extended life
antifreeze/Dex-Cool® and water
Cooling System Capacity: 4.6 L (156 fl oz)
59
2. Indicator line on side of
overflow bottle
Cleaning the Hydraulic-Fluid
Cooler and Radiator Screen
Brake Maintenance
Service Interval: Before each use or daily
Adjusting the Parking
Brake
Before each use, check and clean the radiator screen
and oil cooler. Remove any buildup of grass, dirt or
other debris from the oil cooler and radiator screen
with compressed air (Figure 85).
Service Interval: Every 25 hours
Every 200 hours
1.
Engage the parking brake.
2.
Measure the length of the spring (Figure 86).
Note: The measurement should be 64 mm
(2-1/2 inches) between the washers.
3.
If adjustment is necessary, disengage the
parking brake, loosen the jam nut below the
spring and adjust the nut directly below the
spring (Figure 86).
4.
Turn the nut until the correct measurement is
obtained.
Note: Turn the nut clockwise to shorten spring
length and turn counter-clockwise to lengthen
the spring.
5.
Tighten the 2 nuts together.
6.
Engage the parking brake and check the
measurement of the spring again.
7.
If an adjustment is necessary, repeat the
procedures above.
8.
Repeat on the opposite side of machine.
g001104
Figure 85
1. Hydraulic-fluid cooler
3. Radiator screen
2. Left rear tire
Changing the Engine Coolant
Service Interval: Yearly
Contact an Authorized Service Dealer for changing
the coolant.
g001294
Figure 86
1. Brake lever in engaged
position
2. Spring—64 mm (2-1/2
inches)
60
3. Adjusting nut and jam nut
Belt Maintenance
Inspecting the Belts
7.
Remove the belt guide on the spring-loaded
idler pulley shown in Figure 88.
8.
Remove the existing belt.
9.
Install the new belt around the mower pulleys
and the gearbox pulley under the engine (Figure
88).
Service Interval: Every 100 hours
Check the belts for 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 mower belt if any of these conditions
are evident.
Replacing the Mower Belt
Side Discharge Machines
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 mower 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.
Loosen the bottom bolt holding the mower-deck
curtain to the mower deck; refer to Releasing
the Mower-Deck Curtain (page 42).
4.
Remove the sheet-metal guard; refer to
Removing the Sheet-Metal Guard (page 42).
5.
Remove the belt covers (Figure 87).
g006479
Figure 88
g006541
6.
5. Gearbox pulley
2. Mower spindle pulley
6. Idler spring
3. Spring-loaded idler pulley
7. Idler plate (for 72-inch
mowers only)
4. Belt guide at a 45 degree
angle
Figure 87
1. Belt cover
2. Latch
1. Mower belt
3. Insert slot into the tab
Remove the idler spring.
61
10.
Install the belt guide on the spring-loaded idler
at a 45 degree angle as shown in Figure 88.
Torque the bolt to 37 to 45 N∙m (27 to 33 ft-lb).
11.
Install the idler spring to the 2 posts (Figure 88).
12.
Install the belt covers by sliding the cover into
the tab, install the bolts, and close the latches
(Figure 89).
Replacing the Mower Belt
Rear Discharge Machines
Important: The fasteners on the covers of this
machine are designed to remain on the cover
after removal. Loosen all of the fasteners on
each cover a few turns so that the cover is loose
but still attached, then go back and loosen them
until the cover comes free. This prevents you
from accidentally stripping the bolts free of the
retainers.
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 mower belt if any of these conditions are evident.
g006535
Figure 89
1. Belt cover
2. Latch
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 bottom bolt holding the mower-deck
curtain to the mower deck; refer to Releasing
the Mower-Deck Curtain (page 42).
4.
Remove the sheet metal guard; refer to
Removing the Sheet-Metal Guard (page 42)
5.
Remove the belt covers and the bolts attached
to them.
6.
Loosen the fixed idler arm and adjust it to relieve
belt tension (Figure 90).
7.
Remove the old belt.
8.
Install the new belt on the pulleys.
9.
Insert a ratchet with a short extension or a
breaker bar into the square hole in the fixed idler
arm (Figure 90).
3. Insert slot into the tab
13.
Install the sheet-metal guard.
14.
Tighten the bottom bolt holding the mower-deck
curtain to the mower deck.
62
10.
Adjust the mower deck to the 76 mm (3 inch)
height-of-cut position.
11.
To increase the belt tension, rotate the ratchet or
breaker bar counterclockwise to move the fixed
idler arm until there is 16.5 cm (6-1/2 inches)
between the spring hooks (Figure 90).
16.
Tighten the bolt for the mower-deck curtain; refer
to Releasing the Mower-Deck Curtain (page 42).
17.
Check the tension on the drive belts.
Replacing the PTO-Drive
Belt
Service Interval: Every 50 hours—Check the
PTO-drive belt.
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 front engine panel knobs and
remove the panel (Figure 92).
g005911
Figure 90
1. Ratchet with short
extension or breaker
bar
2. 16.5 cm (6-1/2 inches)
between the spring hooks
3. Spring-loaded idler pulley
4. Fixed Idler pulley
12.
While holding the belt in tension, tighten the 2
bolts that secure the fixed idler arm.
13.
Remove the ratchet or breaker bar from the
square hole in the fixed idler arm.
14.
Install the belt covers with the tabs in the slots.
Install the screws and close the latches (Figure
91).
g001312
Figure 92
1. Knob
g012506
Figure 91
1. Belt cover
2. Latch
15.
3. Bolt
4. Install tab into the slot
Install the sheet-metal guard; refer to Removing
the Sheet-Metal Guard (page 42).
63
2. Front engine panel
4.
Remove the spring from the idler arm (Figure
93).
5.
Remove the clutch stop bracket.
6.
Remove the old PTO-drive belt.
7.
Install the PTO-drive belt around the clutch
pulley and the gearbox pulley (Figure 93).
8.
Intall the rubber clutch stop.
9.
Install the spring to the idler arm (Figure 93).
g007177
Figure 94
g007176
1. Clutch
3. Spring
2. Pump drive belt
4. Spring-loaded idler pulley
Figure 93
1. Gearbox
2. Spring
4. Clutch
5. Rubber clutch stop
3. Spring-loaded idler pulley
6. PTO-drive belt
Replacing and Tensioning
the Alternator Belt
Replacing the Pump Drive
Belt
Replacing the Alternator Belt
Service Interval: Every 50 hours—Check the
alternator belt.
Service Interval: Every 50 hours—Check the pump
drive belt.
If the alternator belt needs to be replace, take your
machine to an Authorized Service Dealer.
Note: Remove the PTO-drive belt first if the pump
drive belt needs to be replaced.
1.
Tensioning the Alternator Belt
Tilt the seat forward and remove the front engine
panel.
1.
Place a handle between the alternator and
cylinder block.
2.
Adjust the alternator to the outside until there
is 7 to 9 mm (1/4 to 11/32 inch) deflection in
the belt between the engine and the alternator
pulleys with 10 kgf (22.1 lb of force) (Figure 95).
2.
Remove the PTO-drive belt.
3.
Remove the spring from the idler arm (Figure
94).
4.
Install the new belt around the engine and
hydraulic pump pulley (Figure 94).
3.
Tighten the alternator bolts.
5.
Install the PTO-drive belt.
4.
6.
Install the spring to the idler arm (Figure 94).
Check the deflection in the belt again and adjust
the belt if needed.
5.
If the deflection is correct, tighten the bottom
and upper bolt (Figure 95).
64
Controls System
Maintenance
Adjusting the Control
Handle Neutral Position
If the motion-control levers do not align, or move
easily into the console notch, adjustment is required.
Adjust each lever, spring and rod separately.
Note: The motion-control levers must be installed
correctly.
g000968
Figure 95
1. Alternator
4. Top bolt
2. Alternator belt
3. Deflection, 7 to 9 mm (1/4
to 11/32 inch) with 10 kgf
(22.1 lb of force)
5. Bottom bolt
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.
Unlatch the seat and tilt the seat forward.
4.
Begin with either the left or right motion-control
lever.
5.
Move the lever to the neutral position but not
locked (Figure 96).
6.
Pull the lever back until the clevis pin (on arm
below pivot shaft) contacts the end of the slot
(just beginning to put pressure on the spring)
as shown in Figure 96.
7.
Check where the control lever is relative to notch
in console (Figure 96).
Note: It should be centered, allowing lever to
pivot outward to the NEUTRAL-LOCK position.
g001046
Figure 96
1. NEUTRAL-LOCK position
3. NEUTRAL position
2. Control lever
8.
65
If adjustment is needed, loosen the nut and jam
nut against the yoke (Figure 97).
9.
Hydraulic System
Maintenance
Apply slight rearward pressure on the
motion-control lever, turn the head of the
adjustment bolt in the appropriate direction until
the control lever is centered in the NEUTRAL-LOCK
position (Figure 97).
Hydraulic System Safety
Note: Keeping rearward pressure on the lever
keeps the pin at the end of the slot and allow
the adjustment bolt to move the lever to the
appropriate position.
• Seek immediate medical attention if fluid is injected
10.
Tighten the nut and jam nut (Figure 97).
•
11.
Repeat for the opposite side of the machine.
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.
•
•
•
Servicing the Hydraulic
System
Hydraulic-Fluid Specifications
Hydraulic-Fluid Type: Toro® HYPR-OIL™ 500
hydraulic fluid or Mobil® 1 15W-50 fluid
g001155
Important: Use the specified fluid. Other fluids
Figure 97
1. Height-of-cut lever
5. Adjustment bolt
2. Nut against yoke
6. Yoke
3. Jam nut
7. Spring
could cause system damage.
Hydraulic-System Fluid Capacity: 3.9 L (132 oz)
Checking the Hydraulic-Fluid
Level
4. Clevis pin in slot
Service Interval: After the first 8 hours
Every 25 hours
Note: You can check the hydraulic fluid when the
fluid is warm or it is cold. The baffle inside the tank
has 2 levels depending if the fluid is warm or cold.
66
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 area around the filler neck of the
hydraulic tank (Figure 98).
4.
Remove the cap from the filler neck and look
inside to check if there is fluid in the reservoir
(Figure 98).
5.
If there is no fluid, add fluid to the reservoir until
it reaches the cold level of the baffle.
6.
Run the machine at low idle for 15 minutes to
allow any air to purge out of the system and
warm the fluid; refer to Starting and Shutting Off
the Engine (page 26).
Replacing the Hydraulic Filter and
Fluid
Service Interval: After the first 25 hours
Every 250 hours—Change the hydraulic filter
and hydraulic fluid when using Mobil® 1 fluid.
Note: Check the fluid level while the fluid is
Every 500 hours—Change the hydraulic
filter and hydraulic fluid when using Toro®
HYPR-OIL™ 500 hydraulic fluid.
warm. The fluid should be between cold and hot.
7.
8.
If required, add fluid to the hydraulic tank.
Note: The fluid level should be to the top of
Use summer filter above 0°C (32°F)
the hot level of the baffle, when the fluid is hot
(Figure 98).
Use winter filter below 0°C (32°F)
Install cap on filler neck.
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.
Important: Do not substitute automotive
oil filter or severe hydraulic system damage
may result.
3.
Place drain pan under filter, remove the old filter
and wipe the filter adapter gasket surface clean
(Figure 99).
g004819
Figure 98
1. Hot fluid level-full
2. Cold fluid level-full
g001044
Figure 99
1. Hydraulic filter
67
4.
Remove the right hydraulic line that comes into
the adapter (Figure 100).
5.
Allow the fluid to drain out of the system into the
drain pan.
6.
Install the right hydraulic line to the adapter
(Figure 100).
g001313
g001043
Figure 100
1. Right hydraulic line
Figure 101
3. Hydraulic tank
1. Hydraulic filter
2. Hydraulic filter
7.
Apply a thin coat to the rubber gasket on the
replacement filter (Figure 101).
8.
Install the replacement hydraulic filter onto the
filter adapter.
Bleeding the Hydraulic System
The traction system is self-bleeding; however, it may
be necessary to bleed the system if fluid is changed
or after work is performed on the system.
Note: Do not tighten.
9.
3. Adapter
2. Gasket
Fill the hydraulic tank with hydraulic fluid until
the fluid overflows the filter and then turn the
fluid filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter
an additional 1/2 turn (Figure 101).
1.
Raise the rear of the machine so that the wheels
are off the ground and support with jack stands.
2.
Start the engine and run at low idle speed and
engage the lever and traction on 1 side and spin
the wheel by hand.
3.
When the wheel begins to spin on its own,
keep it engaged until the wheel drives smoothly
(minimum 2 minutes).
10.
Clean up any spilled fluid.
11.
Add fluid to the cold level of the baffle in the
hydraulic tank.
12.
Start the engine and let it run for about 2 minutes
to purge air from the system.
4.
Check the hydraulic-fluid level and add as
required to maintain proper level.
13.
Shut off the engine and check for leaks.
5.
Repeat this procedure on the opposite wheel.
Note: If 1 or both wheels do not drive, refer to
14.
Bleeding the Hydraulic System (page 68).
Checking the Hydraulic Hoses
Check the fluid level while the fluid is warm.
Service Interval: Every 100 hours
Note: The fluid should be between cold and hot.
15.
Check the hydraulic hoses for leaks, loose fittings,
kinked lines, loose mounting supports, wear, weather
and chemical deterioration. Make necessary repairs
before operating the machine.
If required, add fluid to the hydraulic tank.
Note: Do not overfill.
Note: Keep areas around the hydraulic system clean
from grass and debris buildup.
68
Setting the Hydraulic Pump
Neutral Position
WARNING
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
Note: Adjust the handle neutral first. That needs to
be correct before the following adjustment can be
made.
• If hydraulic fluid is injected into the skin it
must be surgically removed within a few
hours by a doctor familiar with this type of
injury. Gangrene may result if this is not
done.
This adjustment must be made with drive wheels
turning.
DANGER
• Keep body and hands away from pin hole
leaks or nozzles that eject high-pressure
hydraulic fluid.
Mechanical or hydraulic jacks may fail to
support the machine and cause a serious
injury.
• Use a jack stand when supporting the
machine.
• Do not use hydraulic jacks.
• Use cardboard or paper to find hydraulic
leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Make sure that all hydraulic-fluid hoses
and lines are in good condition and all
hydraulic connections and fittings are
tight before applying pressure to hydraulic
system.
WARNING
The engine must be running so that you can
adjust the motion control. Any contact with
moving parts or hot surfaces may cause
personal injury.
Keep your hands, feet, face, clothing and
other body parts away from rotating parts,
muffler and other hot surfaces.
1.
Raise the frame and block up the machine so
that the drive wheels can rotate freely.
2.
Disconnect the electrical connector from the seat
safety switch. Temporarily install a jumper wire
across terminals in the wire-harness connector.
3.
Unlatch the seat and slide seat forward.
4.
Disconnect the seat rod and tilt the seat fully
forward.
Setting the Right Hydraulic Pump
Neutral Position
1.
Start the engine, open the throttle 1/2 way and
disengage parking brake; refer to Starting and
Shutting Off the Engine (page 26).
Note: The motion-control lever must be in
neutral while making any adjustments.
2.
Adjust the pump rod length by rotating the knob,
in the appropriate direction, until the wheel is still
or slightly creeping in reverse (Figure 102).
3.
Move the motion-control lever forward and
reverse, then back to neutral.
Note: The wheel must stop turning or slightly
creep in reverse.
69
4.
Open the throttle to
Setting the Left Hydraulic Pump
Neutral Position
FAST .
Note: Make sure that the wheel remains
stopped or slightly creeps in reverse; adjust if
necessary.
1.
Loosen the locknuts at the ball joints on the
pump control rod (Figure 103).
2.
Start the engine, open the throttle 1/2 way and
disengage parking brake; refer to Starting and
Shutting Off the Engine (page 26).
Note: The motion-control lever must be in
neutral while making any adjustments.
Note: The front nut on the pump rod has
left-hand threads.
3.
Adjust the pump rod length by rotating double
nuts on rod, in the appropriate direction, until
wheel is still or slightly creeps in reverse (Figure
103).
4.
Move the motion-control lever forward and
reverse, then back to neutral. The wheel must
stop turning or slightly creep in reverse.
5.
Open the throttle to fast. Make sure that the
wheel remains stopped or slightly creeps in
reverse, adjust if necessary.
6.
Tighten the locknuts at the ball joints (Figure
103).
g001070
Figure 102
1. Tracking knob
4. Turn this way to track right
2. Hydraulic tank
5. Turn this way to track left
3. Hydraulic pumps
g001066
Figure 103
70
1. Double nuts
2. Pump rod
4. Locknut
5. Ball joint
3. Adjustment bolt
6. Pumps
Mower Deck
Maintenance
WARNING
The electrical system does not perform
proper safety shut off with the jumper
wire installed.
Leveling the Mower at 3
Positions
• Remove the jumper wire from the
wire harness connector and plug the
connector into the seat switch when
you complete the adjustment.
Important: There are only 3 measuring positions
needed to level the mower.
• Never operate the machine with the
jumper installed and the seat switch
bypassed.
1.
Park the machine on a level surface, disengage
the blade-control switch, and engage the parking
brake.
Remove the jumper wire from the wire harness
connector and plug the connector into the seat
switch.
2.
Shut off the engine, remove the key, and wait
for all moving parts to stop before leaving the
operating position.
Install the seat rod and lower the seat into
position.
3.
Check tire pressure of the tires; if needed, adjust
to 90 kPa (13 psi).
4.
Lower the mower to the 76 mm (3 inches)
height-of-cut position.
5.
Inspect the 4 chains.
7.
After both pump neutrals are set, shut off the
machine.
8.
9.
10.
Setting Up the Machine
Remove the jack stands.
Note: The chains need to have tension.
Note: Adjust the rear chains to the top of the
slot, where they are attached to the mower.
• If a rear chain is loose, lower (loosen) the
front-support arm on the same side; refer
to Adjusting the Front-to-Rear Mower Pitch
(page 72).
• If a front chain is loose, raise (tighten) the
front-support arm for that chain; refer to
Adjusting the Front-to-Rear Mower Pitch
(page 72).
71
Leveling the Mower Side-to-Side
1.
Position the right blade side-to-side (Figure
104).
g001040
Figure 105
g006888
Figure 104
1. Measure here from blade
to hard surface
2.
1. Rear chain
5. Adjustment bolt
2. Rear-support arm
6. Front swivel
3. Bolt
7. Front-support arm
4. Jam nut
2. Measure at B and C
8.
Measure the right blade at the B location, from a
level surface to the cutting edge of the blade tip
(Figure 104).
Loosen the jam nut under the rear-support
arm and adjust the adjustment bolt to get a
measurement of 80 to 83 mm (3-1/8 to 3-1/4
inches); refer to Figure 105.
Note: It is recommended that both sides of the
mower are adjusted the same distance.
3.
Record this measurement. This measurement
needs to be 80 to 83 mm (3-1/8 to 3-1/4 inches).
4.
Position the left blade side-to-side (Figure 104).
5.
Measure the left blade at the C location (Figure
104), from a level surface to the cutting edge of
the blade tip.
10.
6.
Record this measurement. This measurement
needs to be 80 to 83 mm (3-1/8 to 3-1/4 inches).
7.
If the measurements at positions B or C are not
correct, loosen the bolt attaching the rear chain
to the rear-support arm (Figure 105).
Adjusting the Front-to-Rear Mower
Pitch
9.
1.
72
Tighten the jam nut under the rear-support arm
and tighten the bolt securing the chain to the
rear-support arm.
Adjust the opposite side if needed.
Position the right blade front-to-rear (Figure
106).
Adjusting the Compression Spring
1.
Raise the mower lift lever to the transport
position.
2.
Check the distance between the 2 large
washers, it needs to be 28.2 cm (11-1/8 inches)
for 52 inch mower decks, 26.7 cm (10-1/2
inches) for 60 inch mower decks, or 29.2 cm
(11-1/2 inches) for 72 inch mower decks (Figure
107).
g001041
Figure 106
1. Measure here from blade
to hard surface
2. Measure at A and B
2.
Measure the right blade at the A location, from a
level surface to the cutting edge of the blade tip
(Figure 106).
3.
Record this measurement.
4.
Measure the right blade at the B location, from a
level surface to the cutting edge of the blade tip
(Figure 106).
5.
Record this measurement.
6.
The mower blade should be 6 to 10 mm (1/4 to
3/8 inch) lower at position A than at position B
(Figure 106). If it is not correct, proceed to the
following steps.
g002479
Figure 107
6. Lift nut
1. 28.2 cm (11-1/8 inches)
between the large washers
for 52 inch mower decks
2. Front nut
7. Front-support arm
3. Spring-jam nut
4. Front swivel
Note: Both of the front swivels need to be
adjusted the same amount to maintain equal
chain tension.
7.
8.
5. Swivel jam nut
Loosen the front swivel jam nuts, at the front of
the right and left swivels, approximately 13 mm
(1/2 inch) (Figure 105).
3.
Adjust the lift nuts on both the left and the right
side of the machine to achieve 6 to 10 mm (1/4
to 3/8 inch) lower in front at A than in the rear
at B (Figure 105).
9.
Tighten both swivel jam nuts against the front
swivel to lock the height.
10.
Check to make sure that there is equal tension
on the chains and adjust again if needed.
8. Large washer
9. 26.7 cm (10-1/2 inches)
between the large washers
for 60 inch mower decks
10. 29.2 cm (11-1/2 inches)
between the large washers
for 72 inch mower decks
Adjust this distance, by loosening the spring-jam
nut and turning the nut in front of each spring
(Figure 107).
Note: Turning the nut clockwise shortens the
spring; counter-clockwise lengthens the spring.
4.
73
Lock the nut into position by tightening the
spring-jam nut (Figure 107).
Servicing the Cutting
Blades
Maintain sharp blades throughout the cutting season
because sharp blades cut 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.
g006530
Check the cutter blades daily 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. For convenient
sharpening and replacement, you may want to keep
extra blades on hand.
Figure 108
1. Cutting edge
3. Wear/slot forming
2. Curved area
4. Crack
Checking for Bent Blades
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.
• Inspect the blades periodically for wear or damage.
• 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.
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 blades until the ends face forward
and backward.
4.
Measure from a level surface to the cutting
edge, position A, of the blades (Figure 109).
• On multi-bladed machines, take care as rotating 1
blade can cause other blades to rotate.
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.
Inspecting the Blades
Service Interval: Before each use or daily
g003177
Figure 109
1.
Inspect the cutting edges (Figure 108).
2.
If the edges are not sharp or have nicks, remove
and sharpen the blade; refer to Sharpening the
Blades (page 75).
3.
Inspect the blades, especially in the curved area.
5.
Rotate the opposite ends of the blades forward.
4.
If you notice any cracks, wear, or a slot forming
in this area, immediately install a new blade
(Figure 108).
6.
Measure from a level surface to the cutting edge
of the blades at the same position as in step 4
above.
1. Measure here from blade
to hard surface
74
2. Position A
Sharpening the Blades
Note: The difference between the dimensions
obtained in steps 4 and 6 must not exceed 3
mm (1/8 inch).
1.
Note: If this dimension exceeds 3 mm (1/8
inch), the blade is bent and must be replaced.
Use a file to sharpen the cutting edge at both
ends of the blade (Figure 111).
Note: Maintain the original angle.
Note: The blade retains its balance if the same
amount of material is removed from both cutting
edges.
WARNING
A blade that is bent or damaged could
break apart and could seriously injure or
kill you or bystanders.
• Always replace a bent or damaged
blade with a new blade.
• Do not file or create sharp notches in
the edges or surfaces of the blade.
g000276
Figure 111
Removing the Blades
1. Sharpen at original angle.
Blades must be replaced if a solid object is hit, if the
blade is out of balance, or if the blade is bent. To
ensure optimum performance and continued safety
conformance of the machine, use genuine Toro
replacement blades. Replacement blades made by
other manufacturers may result in nonconformance
with safety standards.
2.
Check the balance of the blade by putting it on
a blade balancer (Figure 112).
Note: If the blade stays in a horizontal position,
the blade is balanced and can be used.
Note: If the blade is not balanced, file some
metal off the end of the sail area only (Figure
111).
1.
Hold the blade end using a rag or a
thickly-padded glove.
2.
Remove the blade bolt, the curved washer, and
the blade from the spindle shaft (Figure 110).
g000277
Figure 112
1. Blade
3.
g004536
Figure 110
1. Sail area of the blade
2. Blade
3. Curved washer
4. Blade bolt
75
2. Balancer
Repeat this procedure until the blade is
balanced.
Installing the Blades
1.
Install the blade onto the spindle shaft (Figure
113).
Replacing the Grass
Deflector
Important: The curved part of the blade
Side Discharge Machines Only
must be pointing upward toward the inside
of the mower to ensure proper cutting.
2.
WARNING
Install the spring disk and blade bolt (Figure
113).
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.
Note: The spring-disk cone must be installed
toward the bolt head (Figure 113).
3.
• Never operate the machine unless you
install a cover plate, a mulch plate, or a
grass chute and catcher.
Torque the blade bolt to 115 to 150 N∙m (85 to
110 ft-lb).
• Make sure that the grass deflector is in the
down position.
1.
Remove the locknut, bolt, spring and spacer
holding the deflector to the pivot brackets
(Figure 114).
2.
Remove the damaged or worn grass deflector.
3.
Place the spacer and spring onto the grass
deflector. Place the L end of the spring behind
the deck edge.
Note: Make sure that the L end of the spring is
installed behind the deck edge before installing
the bolt as shown in Figure 114
g004536
Figure 113
1. Sail area of the blade
3. Spring disk
2. Blade
4. Blade bolt
4.
Install the bolt and nut.
5.
Place the J-hook end of the spring around the
grass deflector (Figure 114).
Important: The grass deflector must be able
to lower into position. Lift the deflector up to
test that it lowers into the full-down position.
76
Cleaning
Cleaning under the 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.
Raise the mower deck to the TRANSPORT
position.
g002519
Figure 114
1. Bolt
5. Spring installed
2. Spacer
6. Grass deflector
3. Locknut
7. L-end of spring, place
behind deck edge before
installing bolt
4. Spring
8. J-hook end of spring
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.
77
Storage
A.
Run the engine to distribute conditioned fuel
through the fuel system for 5 minutes.
Storage Safety
B.
Shut off the engine, allow it to cool, and
drain the fuel tank; refer to Servicing the
Fuel Tank (page 52).
• 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.
Remove the key and store it in a safe place out
of the reach of children.
•
•
Note: Start the engine and run it until it
shuts off.
C.
Important: Do not store
stabilizer/conditioned fuel longer
than the duration recommended by the
fuel-stabilizer manufacturer.
Cleaning and Storage
1.
2.
3.
Disengage the blade-control switch (PTO),
engage the parking brake, turn the ignition key
to the OFF position, and remove the key.
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: You can wash the machine with
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 the brake; refer to Brake Maintenance
(page 60).
Service the air cleaner; refer to Servicing the Air
Cleaner (page 46).
4.
Grease the machine; refer to Lubrication (page
42).
Change the crankcase oil; refer to Changing the
Engine Oil (page 50).
Check the tire pressure; refer to Checking the
Tire Pressure (page 55).
Change the hydraulic filter; refer to Replacing
the Hydraulic Filter and Fluid (page 67).
Charge the battery; refer to Charging the Battery
(page 54).
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
5.
Dispose of fuel properly. Recycle as per
local codes.
switch (PTO) engaged and the engine at high
idle for 2 to 5 minutes after washing.
Check the condition of the blades; refer to
Inspecting the Blades (page 74).
Prepare the machine for storage when non-use
occurs over 30 days. Prepare the machine for
storage as follows:
78
6.
Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
7.
Paint all scratched or bare metal surfaces. Paint
is available from your Authorized Service Dealer.
8.
Store the machine in a clean, dry garage or
storage area. Remove the key from the ignition
switch and keep it out of reach of children or
other unauthorized users. Cover the machine to
protect it and keep it clean.
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 (PTO) is
engaged.
1. Move the blade-control switch (PTO)
to disengaged.
2. The parking brake is not engaged.
3. The drive levers are not in the
NEUTRAL-LOCK position.
4. The operator is not seated.
5. The battery is dead.
6. The electrical connections are
corroded or loose.
7. The fuse is blown.
8. The relay or switch is broken.
2. Engage the parking brake.
3. Ensure that the drive levers are in the
NEUTRAL-LOCK position.
4. Sit on the 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 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 is 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 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
above the engine are plugged.
2. Add oil to the crankcase.
3. Remove the obstruction from the
cooling fins and air passages.
1. The by pass valves are not closed
tight.
1. Tighten the by pass valves.
2.
3.
4.
5.
2.
3.
4.
5.
8. The seat switch is not functioning
properly.
9. The electrical connections are
corroded, loose or faulty.
The engine loses power.
The engine overheats.
The machine does not drive.
Corrective Action
The pump belt is worn, loose or broken.
The pump belt is off a pulley.
The idler spring is broken or missing.
The hydraulic-fluid level is low or too
hot.
79
Change the belt.
Change the belt.
Replace the spring.
Add hydraulic fluid to reservoirs or let it
cool down.
Problem
There is abnormal vibration.
Mowing is resulting in uneven cutting
height.
Possible Cause
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.
1. The blade(s) is/are not sharp.
1. Sharpen the blade(s).
2. The cutting blade(s) is/are bent.
3. The mower deck is not level.
2. Install new cutting blade(s).
3. Level the mower deck from side-to-side
and front-to-rear.
4. Clean the underside of the mower.
5. Adjust the tire pressure.
6. Contact an Authorized Service Dealer.
4. The underside of mower is dirty.
5. The tire pressure is not correct.
6. The blade spindle bent.
The blades do not rotate.
Corrective Action
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Contact an Authorized Service Dealer.
1. The mower deck belt is worn, loose
or broken.
1. Install a new deck belt.
2. The mower deck belt is off pulley.
2. Install the mower 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.
80
Schematics
g012068
Wire Diagram (Rev. A)
81
Notes:
Notes:
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374-0282 Rev C