Toro TimeCutter ZS 5000 Riding Mower Riding Product Operator's Manual

Add to my manuals
64 Pages

advertisement

Toro TimeCutter ZS 5000 Riding Mower Riding Product Operator's Manual | Manualzz

Form No. 3425-565 Rev A

TimeCutter ® ZS 4200T or ZS 5000

Riding Mower

Model No. 74686—Serial No. 400000000 and Up

Model No. 74688—Serial No. 400000000 and Up

Register at www.Toro.com.

Original Instructions (EN)

*3425-565* A

This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.

Gross or Net Torque: The gross or net torque of this engine was laboratory rated by the engine manufacturer in accordance with the Society of

Automotive Engineers (SAE) J1940 or J2723. As configured to meet safety, emission, and operating requirements, the actual engine torque on this class of mower will be significantly lower. Please refer to the engine manufacturer’s information included with the machine.

Go to www.Toro.com to view specifications on your model.

Important: If you are using a machine with a Toro engine above 1500 m (5,000 ft) for a continuous period, ensure that the High Altitude Kit has been installed so that the engine meets CARB/EPA emission regulations. The High Altitude Kit increases engine performance while preventing spark-plug fouling, hard starting, and increased emissions. Once you have installed the kit, attach the high-altitude label next to the serial decal on the machine. Contact any Authorized Toro Service

Dealer to obtain the proper High Altitude Kit and high-altitude label for your machine. To locate a dealer convenient to you, access our website at www.Toro.com or contact our Toro Customer

Care Department at the number(s) listed in your

Emission Control Warranty Statement.

Remove the kit from the engine and restore the engine to its original factory configuration when running the engine under 1500 m (5,000 ft). Do not operate an engine that has been converted for high-altitude use at lower altitudes; otherwise, you could overheat and damage the engine.

If you are unsure whether or not your machine has been converted for high-altitude use, look for the following label.

Introduction

This rotary-blade, riding lawn mower is intended to be used by homeowners in residential applications. It is designed primarily for cutting grass on well-maintained lawns.

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.

Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.

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 on the serial number decal (if equipped) to access warranty, parts, and other product information.

Figure 2 decal127-9363

Figure 1

Under the seat

1.

Model and serial number location

Write the product model and serial numbers in the space below: g266235

Model No.

Serial No.

© 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

This manual uses 2 words to highlight information.

Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

Contents

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

Safety Alert Symbol ............................................ 4

General Safety ................................................... 5

Slope Indicator ................................................... 6

Safety and Instructional Decals .......................... 7

Product Overview ................................................... 15

Controls ........................................................... 15

Before Operation ................................................. 17

Before Operation Safety ................................... 17

Pre-Start ........................................................... 17

Fuel Safety ....................................................... 18

Adding Fuel ...................................................... 19

Performing Daily Maintenance.......................... 19

Breaking in a New Machine .............................. 19

Using the Safety-Interlock System .................... 20

Positioning the Seat.......................................... 20

Adjusting the Motion-Control Levers ................. 21

Converting to Side Discharge ........................... 21

During Operation ................................................. 24

During Operation Safety ................................... 24

Operating the Mower Blade-Control Switch

(PTO) ............................................................ 26

Operating the Throttle....................................... 27

Operating the Choke......................................... 27

Starting the Engine ........................................... 28

Shutting Off the Engine..................................... 28

Using the Motion-Control Levers....................... 28

Driving the Machine .......................................... 28

Using the Side Discharge ................................. 30

Adjusting the Height of Cut ............................... 31

Adjusting the Anti-Scalp Rollers........................ 31

Operating Tips ................................................. 32

After Operation .................................................... 33

After Operation Safety ...................................... 33

Pushing the Machine by Hand .......................... 36

Maintenance ........................................................... 37

Recommended Maintenance Schedule(s) ........... 37

Maintenance Safety.......................................... 37

Pre-Maintenance Procedures .............................. 39

Raising the Seat ............................................... 39

Releasing the Mower-Deck Curtain .................. 39

Lubrication .......................................................... 39

Greasing the Bearings ...................................... 39

Engine Maintenance ........................................... 40

Engine Safety ................................................... 40

Servicing the Air Cleaner .................................. 40

Servicing the Engine Oil.................................... 42

Servicing the Spark Plug................................... 44

Cleaning the Cooling System............................ 45

Fuel System Maintenance ................................... 45

Replacing the In-Line Fuel Filter ....................... 45

Electrical System Maintenance ........................... 46

Electrical System Safety ................................... 46

Servicing the Battery......................................... 46

Servicing the Fuses .......................................... 48

Drive System Maintenance .................................. 48

3

Checking the Tire Pressure............................... 48

Releasing the Electric Brake ............................. 49

Belt Maintenance ................................................ 49

Inspecting the Belts .......................................... 49

Replacing the Mower-Deck Belt........................ 49

Mower Maintenance............................................. 51

Blade Safety ..................................................... 51

Servicing the Cutting Blades ............................. 51

Leveling the Mower Deck.................................. 53

Removing the Mower Deck ............................... 55

Installing the Mower Deck................................. 56

Replacing the Grass Deflector .......................... 56

Cleaning .............................................................. 57

Washing the Underside of the Mower

Deck.............................................................. 57

Disposing of Waste........................................... 58

Storage ................................................................... 58

Storage Safety.................................................. 58

Cleaning and Storage ....................................... 58

Storing the Battery ............................................ 59

Troubleshooting ...................................................... 60

Schematics ............................................................. 62

Safety

This machine has been designed in accordance with

EN ISO 5395:2013.

Safety Alert Symbol

This Safety Alert Symbol ( Figure 3

) is used both in this manual and on the machine to identify important safety messages which must be followed to avoid accidents.

This symbol means: ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED!

Figure 3

Safety Alert Symbol g000502

The safety alert symbol appears above information which alerts you to unsafe actions or situations and will be followed by the word DANGER , WARNING , or

CAUTION .

DANGER : Indicates an imminently hazardous situation which, if not avoided, Will result in death or serious injury.

WARNING : Indicates a potentially hazardous situation which, if not avoided, Could result in death or serious injury.

CAUTION : Indicates a potentially hazardous situation which, if not avoided, May result in minor or moderate injury.

This manual uses two other words to highlight information.

Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

4

General Safety

This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death.

• Read, understand, and follow all instructions and warnings in the Operator’s Manual and other training material, on the machine, engine, and attachments. All operators and mechanics should be trained. If the operator(s) or mechanic(s) can not read this manual, it is the owner’s responsibility to explain this material to them; other languages may be available on our website.

• Only allow trained, responsible, and physically capable operators that are familiar with the safe operation, operator controls, and safety signs and instructions to operate the machine. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• Do Not operate the machine near drop-offs, ditches, embankments, water, or other hazards, or on slopes greater than 15 degrees.

• Do Not put your hands or feet near moving components of the machine.

• Never operate the machine with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition.

• Stop the machine, shut off the engine, and remove the key before servicing, fueling, or unclogging the machine.

5

Slope Indicator

Figure 4

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 g011841

6

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

2.

No fire, open flame, or smoking

3.

Caustic liquid/chemical burn hazard

4.

Wear eye protection.

5.

Read the Operator's

Manual.

6.

Keep bystanders a safe distance away from the battery.

7.

Wear eye protection; explosive gases can cause blindness and other injuries.

8.

Battery acid can cause blindness or severe burns.

9.

Flush eyes immediately with water and get medical help fast.

10.

Contains lead; do not discard

99-3943

For Models with 127 cm (50 inch) Decks

1.

Engine decal99-3943 decaloemmarkt

Manufacturer's Mark

1.

Indicates the blade is identified as a part from the original machine manufacturer.

decal93-7009

93-7009

1.

Warning—do not operate the mower with the deflector up or removed; keep the deflector in place.

2.

Cutting/dismemberment hazard of hand or foot, mower blade—stay away from moving parts.

105-7015

For Models with 107 cm (42-inch) Decks

1.

Belt routing decal105-7015

7

decal106-8717

106-8717

1.

Read the instructions before servicing or performing maintenance.

2.

Check tire pressure every 25 operating hours.

3.

Grease every 25 operating hours.

4.

Engine

1.

Parking position

2.

Fast

3.

Slow

119-8815

4.

Neutral

5.

Reverse decal119-8815 decal112-9840

112-9840

For Models with 127 cm (50 inch) Decks

1.

Read the Operator's

Manual .

3.

Remove the key and read the instructions before servicing or performing maintenance.

2.

Height of cut

1.

Parking position

2.

Fast

3.

Slow

119-8814

4.

Neutral

5.

Reverse decal119-8814

120-5469

For Models with 107 cm (42 inch) Decks

1.

Height of cut decal120-5469

8

120-5470

For Models with 127 cm (50 inch) Decks

1.

Height of cut decal120-5470

9

1.

Fast

2.

Continuous-variable setting

3.

Slow

121-0772

For Models with 107 cm (42 inch) Decks

4.

Choke

5.

Power takeoff (PTO), blade-control switch decal121-0772

10

1.

Fast

2.

Continuous-variable setting

3.

Slow

121-0773

For Models with 127 cm (50 inch) Decks

4.

Choke

5.

Power takeoff (PTO), blade-control switch decal121-0773

11

decal121-2989b

121-2989

1.

Bypass lever position for pushing the machine

2.

Bypass lever position for operating the machine

1.

Oil drain

131-1097 decal131-1097

131-3948

1.

Slow

2.

Towing

131-3948

3.

Fast decal131-3948

12

decal132-0869

132-0869

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.

1.

Warning—read the

Operator's Manual .

2.

Warning—before servicing, engage the parking brake, remove the key and the spark plug connection.

3.

Cutting hazard of hand, mower blade; pinching hazard of hand, belt—keep hands and feet away from moving parts; keep all guards and shields in place.

4.

Thrown object hazard—keep bystanders away from the machine; remove debris from the area before mowing; keep the deflector shield down.

5.

Ramp tipping hazard—when loading onto a trailer, do not use dual ramps; use only a single ramp wide enough for the machine and that has an incline less than

15 degrees; back up the ramp (in reverse) and drive forward off the ramp.

6.

Bodily harm hazard—no riders; look behind you when mowing in reverse.

7.

Tipping hazard on slopes—do not use on slopes near open water; do not use on slopes greater than 15 degrees.

13

decal132-0872

132-0872

1.

Thrown object hazard—keep bystanders away from the machine.

2.

Thrown object hazard, raised baffle—do not operate the machine with an open deck; use a bagger or a baffle.

3.

Severing hazard of hand or foot—keep away from moving parts.

4.

Entanglement hazard—keep away from moving parts; keep all guards and shields in place.

decal138-2456

1.

Read the Operator’s

Manual .

2.

Park the machine on a level surface when filling the fuel tank.

138-2456

3.

Do not overfill the fuel tank.

14

Product Overview

g027829

1.

Height-of-cut lever

2.

Motion-control levers

3.

Operator seat

4.

Smart Speed ™ lever

5.

Mower deck

6.

Anti-scalp roller

7.

Front caster wheels

8.

Footrest

Figure 5

9.

Fuel-tank cap

10.

Engine

11.

Control panel

12.

Deflector

13.

Rear drive wheel

14.

Engine guard

Controls

Become familiar with all the controls before you start the engine and operate the machine.

Control Panel

1.

Throttle control

2.

Choke control

Key Switch

The key switch, used to start and shut off the engine, has 3 positions: O FF , R UN , and S TART . Refer to

Starting the Engine (page 28)

.

Throttle Control

The throttle controls the engine speed, and it has a continuous-variable setting from the S

LOW to F

AST position (

Figure 6 ).

Choke Control

Use the choke control to start a cold engine.

Figure 6

3.

Blade-control switch

(power takeoff)

4.

Key switch g032603

Blade-Control Switch (Power

Takeoff)

The blade-control switch, represented by a power-takeoff (PTO) symbol, engages and disengages power to the mower blades (

Figure 6

).

15

Motion-Control Levers

Use the motion-control levers to drive the machine

forward, reverse, and turn either direction ( Figure 5 ).

Park Position

Move the motion-control levers outward from the center to the P

ARK position when exiting the machine

(

Figure 26

). Always position the motion-control levers into the P

ARK position when you stop the machine or leave it unattended.

Height-of-Cut Lever

Use the height-of-cut lever to lower and raise the deck from the seated position. Moving the lever up (toward you) raises the deck from the ground and moving the lever down (away from you) lowers the deck toward the ground. Adjust the height-of-cut only while the

machine is not moving ( Figure 30

).

Smart Speed ™ Control System

Lever

The Smart Speed ™ Control-System lever, located below the operating position, gives you a choice to drive the machine at 3 speed ranges— trim, tow, and mow (

Figure 29 ).

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.

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.

Fuel-Presence Window

You can use the fuel window, located on the left side of the machine, to verify the presence of fuel in the

tank ( Figure 7

).

1.

Fuel-presence window

Figure 7 g014521

16

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Before Operation

Before Operation Safety

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by Toro.

• Inspect the area where the equipment is to be used and remove all rocks, toys, sticks, wires, bones, and other foreign objects. These can be thrown or interfere with the operation of the machine and may cause personal injury to the operator or bystanders.

• Wear appropriate personal protective equipment such as safety glasses, substantial slip-resistant footwear, and hearing protection. Tie back long hair and avoid loose clothing and loose jewelry which may get tangled in moving parts.

Pre-Start

Fill fuel tank on level ground. See Fuel

Recommendations in the Specifications section for additional gasoline information.

Do Not add oil to gasoline.

Do Not overfill fuel tank. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

Make sure you understand the controls, their locations, their functions, and their safety requirements.

Refer to the Maintenance section and perform all the necessary inspection and maintenance steps.

CAUTION

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.

Wear hearing protection when operating this machine.

• Check that the operator presence controls, safety switches, and shields are attached and functioning properly. Do Not operate unless they are functioning properly.

• Do Not operate the mower when people, especially children, or pets are in the area. Stop the machine and attachment(s) if anyone enters the area.

• Do Not operate the machine without the entire grass collection system, discharge deflector, or other safety devices in place and in proper working condition. Grass catcher components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check for worn or deteriorating components and replace them with the manufacturer’s recommended parts when necessary.

17

Fuel Safety

Use extreme care when handling fuel.

DANGER

In certain conditions gasoline is extremely flammable and vapors are explosive.

A fire or explosion from gasoline can burn you, others, and cause property damage.

• Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold.

Wipe up any gasoline that spills.

• Never refill the fuel tank or drain the machine indoors or inside an enclosed trailer.

• Do Not fill the fuel tank completely full.

Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows gasoline to expand. Overfilling may result in fuel leakage or damage to the engine or emission system.

• Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by spark.

• Store gasoline in an approved container and keep it out of the reach of children.

• Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel when engine is running or when the engine is hot.

• If fuel is spilled, Do Not attempt to start the engine. Move away from the area of the spill and avoid creating any source of ignition until fuel vapors have dissipated.

• Do Not operate without entire exhaust system in place and in proper working condition.

DANGER

In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage.

• Always place gasoline containers on the ground away from your vehicle before filling.

• Do Not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas-powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete. Do Not use a nozzle lock open device.

WARNING

Gasoline is harmful or fatal if swallowed.

Long-term exposure to vapors has caused cancer in laboratory animals. Failure to use caution may cause serious injury or illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank/container opening.

• Keep away from eyes and skin.

• Never siphon by mouth.

To help prevent fires:

• Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas.

• Clean up oil and fuel spills and remove fuel soaked debris.

• Allow the machine to cool before storing the machine in any enclosure. Do Not store near flame or any enclosed area where open pilot lights or heat appliances are present.

18

Adding Fuel

Note: Do not fill the fuel tank completely full.

The empty space in the tank allows the fuel to expand.

Recommended Fuel

• For best results, use only clean, fresh (less than

30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

• Ethanol : Gasoline with up to 10% ethanol

(gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and

MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.

Never use gasoline that contains more than

10% ethanol by volume , such as E15 (contains

15% ethanol), E20 (contains 20% ethanol), or E85

(contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.

• Do not add oil to gasoline.

g027243

Figure 8

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps fuel fresh longer when used as directed by the fuel-stabilizer manufacturer

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

Important: Do not use fuel additives containing methanol or ethanol.

Add the correct amount of fuel stabilizer/conditioner to the fuel.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Performing Daily

Maintenance

Before starting the machine each day, perform the

Each Use/Daily procedures listed in

Maintenance

(page 37)

.

Breaking in a New Machine

New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow

40 to 50 hours of break-in time for new machines to develop full power and best performance.

Filling the Fuel Tank

1.

Park the machine on a level surface.

2.

Engage the parking brake.

3.

Shut off the engine and remove the key.

4.

Clean around the fuel-tank cap.

5.

Fill the fuel tank to the bottom of the filler neck

(

Figure 8

).

19

Using the Safety-Interlock

System

motion-control levers to the center, unlocked position, engage the blade-control switch, and rise slightly from the seat; the engine should shut off.

WARNING

If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.

Understanding the

Safety-Interlock System

The safety-interlock system is designed to prevent the engine from starting unless:

• The blade-control switch (PTO) is disengaged.

• The motion-control levers are in the P ARK position.

The safety-interlock system also is designed to shut off the engine whenever the control levers are out of the P ARK position and you rise from the seat.

Positioning the Seat

The seat can move forward and backward. Position the seat where you have the best control of the

machine and are most comfortable ( Figure 9 ).

Testing the Safety-Interlock

System

Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized

Service Dealer repair the safety system immediately.

1.

Sit on the seat, move the motion-control levers in the P

ARK position, and move the blade-control switch to the O

N position. Try starting the engine; the engine should not crank.

2.

Sit on the seat and move the blade-control switch to the O

FF position. Move either motion-control lever to the center, unlocked position. Try starting the engine; the engine should not crank.

Repeat with the other motion-control lever.

3.

Sit on the seat, move the blade-control switch to the O

FF position, and lock the motion-control levers in the P ARK position. Start the engine.

While the engine is running, engage the blade-control switch, and rise slightly from the seat; the engine should shut off.

4.

Sit on the seat, move the blade-control switch to the O FF position, and lock the motion-control levers in the P ARK position. Start the engine.

While the engine is running, move the

Figure 9 g027249

20

Adjusting the

Motion-Control Levers

Adjusting the Height

You can adjust the motion-control levers higher or lower for maximum comfort (

Figure 10

).

Figure 10

Converting to Side

Discharge

Machines with 107 cm (42-inch)

Mower Decks

The mower deck and mower blades shipped with the machine were designed for optimum mulching and side-discharge performance.

g027252

Removing the Discharge Cover for

Side-Discharging

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 flexible latch from the latch retainer on the discharge cover and pivot the discharge cover to the right (

Figure 11

).

Adjusting the Tilt

You can adjust the motion-control levers forward or rearward for your comfort.

1.

Loosen the upper bolt holding the control lever to the control-arm shaft.

2.

Loosen the lower bolt just enough to pivot the

control lever forward or rearward ( Figure 10 ).

3.

Tighten both bolts to secure the control lever in the new position.

4.

Repeat the adjustment for the other control lever.

g230251

1.

Latch retainer

2.

Latch

Figure 11

3.

Discharge cover

4.

Release the hook-shaped latch on top of the

discharge cover from the pivot rod ( Figure 15 ).

5.

Angle the metal tab on the discharge cover out of the slot in the bracket welded to the mower deck (

Figure 12 ).

21

g230249

Figure 14

1.

Discharge cover

2.

Metal tab

Figure 12

3.

Bracket on the mower deck g230250

5.

On the top of the discharge cover, engage the hook-shaped latch around the pivot rod of the

deflector assembly ( Figure 15

).

Installing the Discharge Cover for Mulching

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.

Angle the metal tab on the discharge cover into the slot in the bracket welded to the mower deck

(

Figure 13

).

g230253

1.

Deflector

2.

Latch

Figure 15

3.

Pivot rod

4.

Discharge cover

1.

Discharge cover

2.

Metal tab

Figure 13

3.

Bracket on the mower deck g230248

4.

Pivot the discharge cover back and toward the deck so that the discharge cover aligns with the

mower deck ( Figure 14

).

6.

Secure the discharge cover to the deck by hooking the flexible latch on the discharge cover

into the retainer on the deck ( Figure 11 ).

Machines with 127 cm (50-inch)

Mower Decks

The mower deck and mower blades shipped with the machine were designed for optimum mulching and side-discharge performance.

22

Removing the Right Baffle for

Side-Discharging

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 right mower blade; refer to

Removing the Blades (page 52)

.

4.

Remove the 2 knobs and curved washers that secure the right baffle to the mower (

Figure 16

).

1.

Knob

2.

Curved washer g005655

Figure 16

3.

Baffle stud coming through the mower

5.

Remove the right baffle and lower the grass deflector over the discharge opening as shown in

Figure 16

and

Figure 17

.

Figure 17

1.

Right baffle

2.

Curved washer and knob

3.

Discharge opening g024261

6.

Install fasteners into the holes in the top of the mower to prevent flying debris.

WARNING

Open holes in the machine expose you and others to thrown debris that can cause severe injury.

• Never operate the machine without hardware mounted in all holes in the machine housing.

• Install the hardware in the mounting holes when you remove the mulching baffle.

7.

Install the right mower blade; refer to

Installing the Blades (page 53)

.

8.

Lift up the grass deflector. Install 2 bolts (5/16 x

3/4 inch) to the 2 holes along the deck cutout.

9.

Install the cutoff baffle to the mower deck (

Figure

18 ).

Note: Use the 2 locknuts (5/16 inch) to secure the baffle to the mower deck.

Note: The cutoff baffle was shipped with the machine as a loose part.

23

1.

Bolt (5/16 x 3/4 inch)

2.

Cutoff baffle

Figure 18

3.

Locknut (5/16 inch) g015321

During Operation

During Operation Safety

General Safety

The operator must use their full attention when operating the machine.

Do Not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

WARNING

Operating engine parts, especially the muffler, become extremely hot. Severe burns can occur on contact and debris, such as leaves, grass, brush, etc. can catch fire.

• Allow engine parts, especially the muffler, to cool before touching.

• Remove accumulated debris from muffler and engine area.

10.

Torque the fasteners to 7 to 9 N∙m (14 to 18 ft-lb).

11.

Lower the grass deflector over the discharge opening.

Important: Ensure that the mower has a hinged grass deflector that disperses clippings to the side and down toward the turf while in side-discharge mode.

Installing the Right Baffle for Mulching

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 cutoff baffle from the mower deck

(

Figure 18

).

4.

Remove the right mower blade; refer to

Removing the Blades (page 52)

.

5.

Slide the right baffle under the mower deck, and secure it using 2 knobs and the curved washers

(cupped side facing the mower) as shown in

Figure 16

and

Figure 17 .

Important: Ensure that the tab on the far right side of the right baffle is outside of the mower and is flush with the mower wall.

6.

Install the right mower blade; refer to

Installing the Blades (page 53)

.

WARNING

Engine exhaust contains carbon monoxide, which is an odorless deadly poison that can kill you.

Do Not run engine indoors or in a small confined area where dangerous carbon monoxide fumes can collect.

• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.

• This mower was designed for one operator only.

Do not carry passengers and keep all others away from machine during operation.

• Do Not operate the machine under the influence of alcohol or drugs.

• Operate only in daylight or good artificial light.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area,

Do Not operate the machine; seek shelter.

• Use extra care while operating with accessories or attachments, such as grass collection systems.

These can change the stability of the machine and cause a loss of control. Follow directions for counter weights if required.

• Keep away from holes, ruts, bumps, rocks, and other hidden hazards. Use care when approaching blind corners, shrubs, trees, tall grass or other objects that may hide obstacles or obscure vision.

Uneven terrain could overturn the machine or cause the operator to lose their balance or footing.

24

• Be sure all drives are in neutral and parking brake is engaged before starting engine.

• Start the engine carefully according to instructions with feet well away from the blades.

• Never operate the mower with damaged guards, shields, or covers. Always have safety shields, guards, switches and other devices in place and in proper working condition.

• Keep clear of the discharge opening at all times.

Never mow with the discharge door raised, removed or altered unless there is a grass collection system or mulch kit in place and working properly.

• Keep hands and feet away from moving parts.

If possible, Do Not make adjustments with the engine running.

WARNING

Hands, feet, hair, clothing, or accessories can become entangled in rotating parts.

Contact with the rotating parts can cause traumatic amputation or severe lacerations.

– Do Not operate the machine without guards, shields, and safety devices in place and working properly.

– Keep hands, feet, hair, jewelry, or clothing away from rotating parts.

• Never raise the deck with blades running.

• Be aware of the mower discharge path and direct discharge away from others. Avoid discharging material against a wall or obstruction as the material may ricochet back toward the operator.

Stop the blades, slow down, and use caution when crossing surfaces other than grass and when transporting the mower to and from the area to be mowed.

• Be alert, slow down and use caution when making turns. Look behind and to the side before changing directions. Do Not mow in reverse unless absolutely necessary.

• Do Not change the engine governor setting or overspeed the engine.

• Park the machine on level ground. Stop engine, wait for all moving parts to stop, and remove the spark plug wire(s).

– Before checking, cleaning or working on the mower.

– After striking a foreign object or abnormal vibration occurs (inspect the mower for damage and make repairs before restarting and operating the mower).

– Before clearing blockages.

– Whenever you leave the mower. Do Not leave a running machine unattended.

• Stop engine, wait for all moving parts to stop:

– Before refueling.

– Before dumping the grass catcher.

– Before making height adjustments.

• Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them.

– Keep children out of the mowing area and under the watchful care of another responsible adult, not the operator.

– Be alert and turn the machine off if children enter the area.

– Before and while backing or changing direction, look behind, down, and side-to-side for small children.

– Never allow children to operate the machine.

– Do Not carry children, even with the blades shut off. Children could fall off and be seriously injured or interfere with the safe operation of the machine. Children that have been given rides in the past could suddenly appear in the working area for another ride and be run over or backed over by the machine.

Slope Safety

• Slopes are a major factor related to loss of control and rollover accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, the operator must:

– Review and understand the slope instructions in the manual and on the machine.

– Use an angle indicator to determine the approximate slope angle of the area.

– Never operate on slopes greater than 15 degrees.

– Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Use common sense and good judgment when performing this evaluation.

Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.

• Identify hazards at the base of the slope. Do

Not operate the machine near drop offs, ditches, embankments, water or other hazards. The machine could suddenly roll over if a wheel goes over the edge or the edge collapses. Keep a safe

25

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.

Operating the Mower

Blade-Control Switch (PTO)

The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.

Engaging the Blade-Control

Switch (PTO)

g008945

Figure 20

Figure 19

1.

Safe Zone-Use the mower here on slopes less than 15 degrees

2.

Danger Zone-Use a walk-behind mower and/or hand trimmer on slopes greater than 15 degrees

3.

Water

4.

W=width of the machine

5.

Keep a safe distance (twice the width of the machine) between the machine and any hazard.

g221745

Note: Always engage the blades with the throttle in the F AST

position ( Figure 21 ).

• 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 counter weights.

• If possible, keep the deck lowered to the ground while operating on slopes. Raising the deck while operating on slopes can cause the machine to become unstable.

Figure 21

Disengaging the Blade-Control

Switch (PTO)

Figure 22 g187516 g009174

26

Operating the Throttle

You can move the throttle control between F

AST and

S

LOW positions (

Figure 23 ).

Always use the F

AST position when engaging the PTO.

Operating the Choke

Use the choke to start a cold engine.

1.

Pull up the choke knob to engage the choke before using the key switch (

Figure 24

).

Note: Ensure that you fully engage the choke.

You may need to hold the knob up when you use the key switch.

2.

Push down the choke to disengage the choke

after the engine has started ( Figure 24

).

g187517

Figure 23

1.

O N position

Figure 24

2.

O FF position g008959

27

Starting the Engine

Note: A warm or hot engine may not require choking.

Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.

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.

Using the Motion-Control

Levers

g004532

Figure 25 g027581

Figure 26

1.

Motion-control lever—P ARK position

4.

Backward

2.

Center, unlocked position 5.

Front of machine

3.

Forward

Shutting Off the Engine

1.

Disengage the blades by moving the blade-control switch to the O

FF

position ( Figure

22 ).

2.

Engage the parking brake; refer to

Park Position

(page 16)

.

3.

Move the throttle control to the F AST position.

4.

Turn the key to the O FF position and remove the key.

Driving the Machine

The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require sometime for you to adapt to how it moves.

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the F AST position for best

28

performance. Always operate in the full throttle position when mowing.

WARNING

The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine.

• Use caution when making turns.

• Slow the machine down before making sharp turns.

Driving Forward

Note: Always use caution when backing up and turning.

1.

Move the levers to the center, unlocked position.

2.

To go forward, slowly push the motion-control levers forward (

Figure 27 ).

g008953

Figure 28

Using the Smart Speed

TM

Control

System

The Smart Speed TM Control-System lever, located

below the operating position ( Figure 29

), gives the operator a choice to drive the machine at 3 ground speed ranges—trim, tow, and mow.

g008952

Figure 27 g027625

Figure 29

Driving Backward

1.

Move the levers to the center, unlocked position.

2.

To go backward, slowly pull the motion-control levers rearward (

Figure 28 ).

1.

Smart-speed lever

To change speeds, do the following:

1.

Move the motion-control levers to neutral and outward to the P ARK position.

2.

Disengage the blade-control switch.

3.

Adjust the lever to the desired position.

The following are only recommendations for use.

Adjustments vary by grass type, moisture content, and the height of the grass.

29

Suggested uses:

Parking

Heavy, wet grass

Training

Trimming grass

Bagging

Mulching

Towing attachments

Normal mowing

Moving the machine

Trim

X

X

X

X

Tow

X

X

X

Mow

X

X

Trim

This is the lowest speed. The suggested uses for this speed are as follows:

• Parking

• Heavy, wet grass mowing conditions

• Training

• Trimming grass

Tow

This is the medium speed. The suggested uses for this speed are as follows:

• Bagging

• Mulching

• Towing attachments

Mow

This is the fastest speed. The suggested uses for this speed are as follows:

• Normal mowing

• Moving the machine

Using the Side Discharge

The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

DANGER

Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• 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 O FF position, rotate the key switch to the O FF position, and remove the key from the key switch.

• Make sure that the grass deflector is in the down position.

30

Adjusting the Height of Cut

Note: The transport position is the highest height-of-cut position or cutting height at 115 mm

(4-1/2 inches) as shown in

Figure 30

.

Height of cut is controlled by the lever located to the right of the operating position (

Figure 30

).

Adjusting the Anti-Scalp

Rollers

Adjusting the Anti-Scalp Rollers

Machines with 107 cm (42-inch) Mower Decks

Whenever you change the height of cut, adjust the height of the anti-scalp rollers.

Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas.

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 to 1 of the following positions:

• Upper hole—use this position with the mower deck in the 63 mm (2-1/2 inches) and below the height-of-cut positions (

Figure 31

).

• Lower hole—use this position with the mower deck in the 76 mm (3 inches) and above the

height-of-cut positions ( Figure 31 ).

Figure 30 g027697 g019929

1.

Anti-scalp roller

2.

Lower hole—the mower deck in the 76 mm (3 inches) and above the height-of-cut positions

3.

Flange nut

Figure 31

4.

Upper hole—the mower deck in the 63 mm (2-1/2 inches) and below the height-of-cut positions

5.

Bolt

31

Adjusting the Anti-Scalp Rollers

Machines with 127 cm (50-inch) Mower Decks

Whenever you change the height of cut, adjust the height of the anti-scalp rollers.

Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas.

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 (

Figure 32

) to match the closest height-of-cut position.

1.

Anti-scalp roller

2.

Bolt

Figure 32

3.

Flange nut

4.

Hole spacing g010233

Operating Tips

Using the Fast Throttle Setting

For best mowing and maximum air circulation, operate the engine at the F AST 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.

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.

Cutting a Third of the Grass Blade

It is best to cut only about a third of the grass blade.

Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Alternating the Mowing Direction

Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.

Mowing at Correct Intervals

Grass grows at different rates at different times of the year. To maintain the same cutting height, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height, then mow again 2 days later at a lower height setting.

Using a Slower Cutting Speed

To improve cut quality, use a slower ground speed in certain conditions.

Avoiding Cutting Too Low

When mowing uneven turf, raise the cutting height to avoid scalping the turf.

Stopping the Machine

If you must stop the forward motion of the machine while mowing, a clump of grass clippings may

32

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.

After Operation

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.

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.

After Operation Safety

General Safety

• Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning, repairing, or storing. Never allow untrained personnel to service machine.

• Clean the machine as stated in the Maintenance section. Keep engine and engine area free from accumulation of grass, leaves, excessive grease or oil, and other debris which can accumulate in these areas. These materials can become combustible and may result in a fire.

• Frequently check for worn or deteriorating components that could create a hazard. Tighten loose hardware.

Transporting

Transporting the Machine

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law.

Thoroughly read all of the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury.

To transport the machine:

• Lock the brake and block the wheels.

• Be sure the fuel shut-off valve is closed.

• Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes. Only use the four designated tie-down locations on the mower–two on the left side and two on the right (

Figure 33 ). Use these locations even

when transporting the mower with an attached accessory. Using non-designated locations may cause damage to the mower and/or attachment.

33

1.

Tie-down location

Figure 33 g027708

• Secure a trailer to the towing vehicle with safety chains.

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 machine on a public street or roadway.

Loading the Machine

Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure.

Back up ramps and drive forward down ramps (

Figure

34 ).

on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle.

WARNING

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death.

• Use extreme caution when operating a machine on a ramp.

• 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 the length of ramp is at least four times (4X) as long as the height of the trailer or truck bed to the ground. This will ensure that ramp angle does not exceed 15 degrees on flat ground.

• Back up ramps and drive forward down ramps.

• 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.

1.

Back up ramps g027995

Figure 34

2.

Drive forward down ramps

Important: Do not use narrow individual ramps for each side of the machine.

Ensure the ramp is long enough so that the angle with the ground does not exceed 15 degrees (

Figure 34

).

On flat ground, this requires a ramp to be at least four times (4X) as long as the height of the trailer or truck bed to the ground. A steeper angle may cause mower components to get caught as the unit moves from the ramp to the trailer or truck. Steeper angles may also cause the machine to tip or lose control. If loading on or near a slope, position the trailer or truck so that it is

34

g027996

Figure 35

1.

Full-width ramp in stowed position

2.

Side view of full-width ramp in loading position

3.

Not greater than

15 degrees

4.

Ramp is at least four times

(4X) as long as the height of the trailer or truck bed to the ground

5.

H= height of the trailer or truck bed to the ground

6.

Trailer

Towing the Machine

• Do not attach towed equipment except at the hitch point.

• Follow the attachment manufacturer's recommendation for weight limits for towed equipment and towing on slopes. Towed weight must not exceed the weight of the machine, operator, and ballast; otherwise hydrostatic transmission failure may occur. Use counterweights or wheel weights as described in the attachment manufacturer's manual.

• Never allow children or others in or on towed equipment.

• On slopes, the weight of the towed equipment may cause loss of traction, increased risk of rollover,

35 and loss of control. Reduce the towed weight and slow down.

• Stopping distance increases with the weight of the towed load. Travel slowly and allow extra distance to stop.

• Make wide turns to keep the attachment clear of the machine.

Pushing the Machine by

Hand

Important: Always push the machine by hand.

Do not tow the machine, because towing may damage it.

This machine has an electric-brake mechanism, and to push the machine, the ignition key must be in the

RUN position. The battery needs to be charged and functioning to disengage the electric brake.

Pushing the Machine

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 bypass levers on the frame on both sides of the engine.

4.

Move the bypass levers forward through the key hole and down to lock them in place (

Figure 36

).

Note: Do this for each lever.

5.

Turn the ignition key on and disengage the parking brake.

Note: Do not start the machine.

brake manually if necessary; refer to

Releasing the

Electric Brake (page 49)

.

Operating the Machine

Move the bypass levers rearward through the keyhole and down to lock them in place as shown in

Figure 36 .

Note: Do this for each lever.

g017303

Figure 36

1.

Bypass-lever locations 3.

Lever position for pushing the machine

2.

Lever position for operating the machine

6.

When finished, ensure that the key has been returned to the STOP position to avoid draining the battery charge.

Note: If the machine fails to move, the electric brake may still be engaged. You can release the electric

36

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the first 5 hours

Before each use or daily

After each use

Every 25 hours

Every 100 hours

Every 200 hours

Before storage

Maintenance Procedure

• Change the engine oil and filter.

• Check the safety-interlock system.

• Check the air cleaner for dirty, loose, or damaged parts.

• Check the engine-oil level.

• Clean the air intake screen.

• Inspect the blades.

• Inspect the grass deflector for damage.

• Clean the mower-deck housing.

• Grease all the lubrication points.

• Clean the air-cleaner foam element (more often in dusty, dirty conditions).

• Check tire pressure.

• Check the belts for wear or cracks.

• Replace the air-cleaner foam element (more often in dusty, dirty conditions).

• Clean the paper air-cleaner element (more often in dirty or dusty conditions).

• Change the engine oil and oil filter (more often in dirty or dusty conditions).

• Check the spark plug(s).

• Check the in-line fuel filter.

• Replace the paper air-cleaner element (more often in dirty or dusty conditions).

• Replace the spark plug(s).

• Replace the in-line fuel filter.

• Charge the battery and disconnect the battery cables.

• Perform all maintenance procedures listed above before storage.

• Paint any chipped surfaces.

CAUTION

If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.

Shut off the engine and remove the key from the switch before you perform any maintenance.

Maintenance Safety

WARNING

While maintenance or adjustments are being made, someone could start the engine. Accidental starting of the engine could seriously injure you or other bystanders.

Remove the key from the ignition switch, engage parking brake, and pull the wire(s) off the spark plug(s) before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

WARNING

The engine can become very hot. Touching a hot engine can cause severe burns.

Allow the engine to cool completely before service or making repairs around the engine area.

37

• Park machine on level ground, disengage drives, set parking brake, stop engine, remove key or disconnect spark plug wire. Wait for all movement to stop and allow the machine to cool before adjusting, cleaning or repairing. Never allow untrained personnel to service machine.

• Disconnect battery or remove spark plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Keep the machine, guards, shields and all safety devices in place and in safe working condition. Frequently check for worn or deteriorating components and replace them with the manufacturer’s recommended parts when necessary.

WARNING

Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.

• Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them.

Only replace damaged blades. Never straighten or weld them.

• Use jack stands to support the machine and/or components when required.

CAUTION

Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the machine to fall, which could cause injury.

Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

• Carefully release pressure from components with stored energy.

• Keep hands and feet away from moving parts. If possible, Do Not make adjustments with the engine running. If the maintenance or adjustment procedure require the engine to be running and components moving, use extreme caution.

WARNING

Contact with moving parts or hot surfaces may cause personal injury.

Keep your fingers, hands, and clothing clear of rotating components and hot surfaces.

• Check all bolts frequently to maintain proper tightness.

38

Pre-Maintenance

Procedures

Raising the Seat

Ensure that the parking brake is engaged. Lift the seat forward.

You can access following components by raising the seat:

• Serial plate

• Service decal

• Seat-adjustment bolts (if applicable)

• Fuel filter

• Battery and battery cables

Releasing the Mower-Deck

Curtain

Loosen the 2 bottom bolts of the curtain to access the top of the mower deck (

Figure 37 ).

Lubrication

Greasing the Bearings

Service Interval: Every 25 hours—Grease all the lubrication points.

Grease Type: No. 2 lithium grease

1.

Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake; refer to

Park Position (page 16)

.

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 (

Figure 38

and

Figure

39 ) with a rag.

Note: Scrape any paint off the front of the fitting(s).

g032432

1.

Front caster tire

Figure 38 g027794

1.

Bottom bolt

Figure 37

2.

Curtain

Note: Always tighten the bolts to connect the curtain after maintenance.

decal106-8717

Figure 39

Located on the seat-pan underside

1.

Read the instructions before servicing or performing maintenance

2.

Check the tire pressure every 25 operating hours

3.

Grease every 25 operating hours

4.

Engine

4.

Connect a grease gun to each fitting (

Figure 38

and

Figure 39

).

5.

Pump grease into the fittings until grease begins to ooze out of the bearings.

6.

Wipe up any excess grease.

39

Engine Maintenance

Engine Safety

• Shut off the engine 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

Service Interval: Before each use or daily

Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper

Elements

1.

Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.

2.

Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Clean around the air-cleaner cover to prevent dirt from getting into the engine and causing damage.

4.

Lift the cover and rotate the air-cleaner assembly out of the engine (

Figure 40

).

Figure 40 g027800 g027801

5.

Separate the foam and paper elements (

Figure

41 ).

Figure 41 g027802

40

Servicing the Foam Air-Cleaner

Element

Service Interval: Every 25 hours/Monthly (whichever comes first)—Clean the air-cleaner foam element (more often in dusty, dirty conditions).

Every 100 hours/Yearly (whichever comes first)—Replace the air-cleaner foam element

(more often in dusty, dirty conditions).

1.

Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.

2.

Dry the element by squeezing it in a clean cloth.

Important: Replace the foam element if it is torn or worn.

Installing the Air Cleaner

1.

Install the foam element over the paper element.

Note: Ensure that you do not damage the elements.

2.

Align the holes of the filter into the manifold ports.

3.

Rotate the filter down into the chamber and fully seat it against the manifold (

Figure 42 ).

Servicing the Paper Air-Cleaner

Element

Service Interval: Every 100 hours—Clean the paper air-cleaner element (more often in dirty or dusty conditions).

Every 200 hours—Replace the paper air-cleaner element (more often in dirty or dusty conditions).

1.

Clean the paper element by tapping it gently to remove dust.

Note: If it is very dirty, replace the paper element with a new one.

2.

Inspect the element for tears, an oily film, or damage to the rubber seal.

3.

Replace the paper element if it is damaged.

Important: Do not clean the paper filter.

4.

Close the cover.

Figure 42 g228022

41

Servicing the Engine Oil

Engine-Oil Specifications

Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL)

Crankcase Capacity: 2.4 L (81 fl oz) with oil filter

Viscosity: See the table below.

g029683

Figure 43

Checking the Engine-Oil Level

Service Interval: Before each use or daily

Note: Check the oil when the engine is cold.

Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.

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.

Note: Ensure that the engine is cool so that the oil has had time to drain into the sump.

3.

To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and

dipstick before removing it ( Figure 44 ).

Figure 44 g193541

Changing the Engine Oil and Oil

Filter

Service Interval: After the first 5 hours/After the first month (whichever comes first)—Change the engine oil and filter.

Every 100 hours/Yearly (whichever comes first)—Change the engine oil and oil filter (more often in dirty or dusty conditions).

1.

Park the machine on a level surface to ensure that the oil drains completely.

2.

Disengage the blade-control switch (PTO) and engage the parking brake.

3.

Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

4.

Drain the oil from the engine.

42

g027799

5.

Change the engine-oil filter (

Figure 46

).

Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn.

Figure 45 g029570

43 g027477

Figure 46

6.

Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the

additional oil to bring it to the Full mark ( Figure

47 ).

g027478

Figure 48

Figure 47 g193530

Checking the Spark Plug

Important: Do not clean the spark plug(s).

Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Set the gap to 0.75 mm (0.03 inch).

7.

Dispose of the used oil at a recycling center.

Servicing the Spark Plug

Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the spark plug(s).

Every 200 hours/Every 2 years (whichever comes first)—Replace the spark plug(s).

Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.

Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type: Champion ® RN9YC or NGK ® BPR6ES

Air gap: 0.76 mm (0.03 inch)

Removing the Spark Plug

1.

Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake.

2.

Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3.

Clean the area around the base of the plug to keep dirt and debris out of the engine.

4.

Remove the spark plug (

Figure 48

).

Figure 49

Installing the Spark Plug

Figure 50 g206628 g027960

44

Cleaning the Cooling

System

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.

Remove the air filter from the engine.

4.

Remove the engine shroud.

5.

To prevent debris entering the air intake, install the air filter to the filter base.

6.

Clean debris and grass from the parts.

7.

Remove the air filter and install the engine shroud.

8.

Install the air filter.

Fuel System

Maintenance

DANGER

In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property.

Refer to

Adding Fuel (page 19)

for a complete list of fuel related precautions.

Replacing the In-Line Fuel

Filter

Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the in-line fuel filter.

Every 200 hours/Every 2 years (whichever comes first)—Replace the in-line fuel filter.

Never install a dirty filter after removing it from the fuel line.

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.

45

Figure 51

Electrical System

Maintenance

g027939

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

g033082

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.

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 seat to access the battery.

4.

Disconnect the negative (black) ground cable from the battery post (

Figure 52

).

Note: Retain all fasteners.

46

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.

5.

Slide the rubber cover off the positive (red) cable.

6.

Disconnect the positive (red) cable from the

battery post ( Figure 52

).

Note: Retain all fasteners.

7.

Remove the battery hold-down (

Figure 52

), and lift the battery from the battery tray.

2.

Charge the battery for a minimum of 1 hour at

6 to 10 A.

Note: Do not overcharge the battery.

3.

When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery

posts ( Figure 53 ).

Figure 53

1.

Positive (+) battery post 3.

Red (+) charger lead

2.

Negative (–) battery post 4.

Black (–) charger lead g000538

Installing the Battery

1.

Position the battery in the tray (

Figure 52

).

2.

Using the fasteners previously removed, install the positive (red) battery cable to the positive

(+) battery terminal.

3.

Using the fasteners previously removed, install the negative battery cable to the negative (-) battery terminal.

4.

Slide the red terminal boot onto the positive

(red) battery post.

5.

Secure the battery with the hold-down (

Figure

52 ).

6.

Lower the seat.

g017701

Figure 52

1.

Battery

2.

Positive (+) battery post

3.

Bolt, washer, and nut

4.

Terminal boot

5.

Negative (–) battery post

6.

Wing nut, washer, and bolt

7.

Battery hold-down

Charging the Battery

Service Interval: Before storage—Charge the battery and disconnect the battery cables.

1.

Remove the battery from the chassis; refer to

Removing the Battery (page 46)

.

47

Servicing the Fuses

The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short.

Fuse type:

• Main—F1 (30 A, blade-type)

• Charge Circuit—F2 (25 A, blade-type)

1.

Remove the screws securing the control panel to the machine.

Note: Retain all fasteners.

2.

Lift the control pane up to access the main wire harness and fuse block (

Figure 54

).

3.

To replace a fuse, pull out the fuse to remove

it ( Figure 54 ).

Drive System

Maintenance

Checking the Tire Pressure

Service Interval: Every 25 hours—Check tire pressure.

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause an uneven

cut. Check the pressure at the valve stem ( Figure 55

).

Check the tires when they are cold to get the most accurate pressure reading.

Refer to the maximum pressure suggested by the tire manufacturer on the sidewall of the caster wheel tires.

Inflate the rear drive-wheel tires to 90 kPa (13 psi).

Figure 54

2.

Charge circuit (25 A) g014921

1.

Main (30 A)

4.

Return the control panel to its original position.

Note: Use the screws removed previously to secure the panel to the machine.

1.

Valve stem

Figure 55 g000554

48

Releasing the Electric

Brake

You can manually release the electric brake by rotating the link arms forward. Once the electric brake is energized, the brake resets.

1.

Turn the key to the OFF position or disconnect the battery.

2.

Loosen the bottom 2 bolts holding the mower-deck curtain to the mower deck. Refer to

Releasing the Mower-Deck Curtain (page 39)

.

3.

Locate the shaft on the electric brake where the

brake link arms are connected ( Figure 56 ).

4.

Rotate the shaft forward to release the brake.

5.

Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck. Refer to

Releasing the Mower-Deck Curtain (page 39)

.

Belt Maintenance

Inspecting the Belts

Service Interval: Every 25 hours—Check the belts for wear or cracks.

Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.

Replacing the Mower-Deck

Belt

The signs of a worn belt include squealing while the belt is rotating, blades slipping while cutting grass, and frayed edges, burn marks, and cracks on the 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 (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.

Set the height-of-cut at the lowest cutting position of 38 mm (1-1/2 inches).

4.

Remove the pulley covers ( Figure 57

).

g027911

Figure 56

1.

Brake-link arm on the electric brake control module

2.

Left, rear tire

49 g032555

1.

Cover

Figure 57

2.

Screw

5.

Loosen the bottom 2 bolts holding the mower-deck curtain to the mower deck. Refer to

Releasing the Mower-Deck Curtain (page 39)

.

6.

Using a spring-removal tool, (Toro Part No.

92-5771), remove the idler spring from the deck hook to remove tension on the idler pulley, and roll the belt off the pulleys (

Figure 58

and

Figure

59 ).

WARNING

The spring is under tension when installed and can cause personal injury.

Be careful when removing the belt.

Figure 59

Mower Decks with 3 Blades

1.

Idler pulley

2.

Mower belt

3.

Outside pulley

4.

Spring

5.

Engine pulley

6.

Spring-removal tool g014931

Figure 58

Mower Decks with 2 Blades

1.

Idler pulley

2.

Mower belt

3.

Outside pulley

4.

Spring

5.

Engine pulley

6.

Spring-removal tool g014930

7.

Route the new belt around the engine pulley and

mower pulleys ( Figure 59

).

8.

Using a spring-removal tool, install the idler spring over the deck hook, and place tension on the idler pulley and mower belt (

Figure 58

and

Figure 59 ).

9.

Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck. Refer to

Releasing the Mower-Deck Curtain (page 39)

.

10.

Install the pulley covers.

50

Mower Maintenance

Blade Safety

A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product.

• 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.

• On multi-bladed machines, take care as rotating 1 blade can cause other blades to rotate.

Servicing the Cutting

Blades

To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand.

1.

Cutting edge

2.

Curved area

Figure 60

3.

Wear/slot forming

4.

Crack g006530

Checking for Bent Blades

Note: The machine must be on a level surface for the following procedure.

1.

Raise the mower deck to the highest height-of-cut position.

2.

While wearing thickly padded gloves, or other adequate hand protection, slowly rotate the blade into a position that allows you to measure the distance between the cutting edge and the level surface the machine is on (

Figure 61

).

Before Inspecting or Servicing the

Blades

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 disconnect the spark-plug wires from the spark plugs.

g014972

1.

Deck

2.

Spindle housing

Figure 61

3.

Blade

Inspecting the Blades

Service Interval: Before each use or daily

1.

Inspect the cutting edges ( Figure 60 ).

2.

If the edges are not sharp or have nicks, remove and sharpen the blade; refer to

Sharpening the

Blades (page 53)

.

3.

Inspect the blades, especially in the curved area.

4.

If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade

(

Figure 60

).

3.

Measure from the tip of the blade to the flat

surface ( Figure 62

).

51

Figure 62

1.

Blade (in position for measuring)

2.

Level surface

3.

Measured distance between blade and the surface (A) g014973 g014973

Figure 64

1.

Opposite blade edge (in position for measuring)

2.

Level surface

3.

Second measured distance between blade and surface (B)

4.

Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (

Figure 63 ).

A.

If the difference between A and B is greater than 3 mm (1/8 inch), replace the blade with a new blade; refer to

Removing the Blades

(page 52)

and

Installing the Blades (page

53)

.

Note: If a bent blade is replaced with a new blade, and the dimension obtained continues to exceed 3 mm (1/8 inch), the blade spindle could be bent. Contact an

Authorized Service Dealer for service.

B.

If the variance is within constraints, move to the next blade.

6.

Repeat this procedure on each blade.

Figure 63

1.

Blade (side previously measured)

2.

Measurement (position used previously)

3.

Opposing side of blade being moved into measurement position g014974

5.

Measure from the tip of the blade to the flat

surface ( Figure 64

).

Note: The variance should be no more than

3 mm (1/8 inch).

Removing the Blades

Replace the blades if they hit a solid object, or if the blade is out of balance or bent.

1.

Hold the blade end using a rag or thickly padded glove.

2.

Remove the blade bolt, curved washer, and

blade from the spindle shaft ( Figure 65 ).

52

Installing the Blades

1.

Install the blade onto the spindle shaft ( Figure

65 ).

Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

2.

Install the curved washer (cupped side toward the blade) and the blade bolt (

Figure 65

).

3.

Torque the blade bolt to 47 to 88 N∙m (35 to 65 ft-lb).

1.

Sail area of the blade

2.

Blade

Figure 65

3.

Curved washer

4.

Blade bolt

Sharpening the Blades

1.

Use a file to sharpen the cutting edge at both

ends of the blade ( Figure 66

).

Note: Maintain the original angle.

Note: The blade retains its balance if the same amount of material is removed from both cutting edges.

g027833

Leveling the Mower Deck

Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.

Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to the

Servicing the Cutting Blades (page 51)

before continuing.

Level the mower deck side-to-side first; then you can adjust the front-to-rear slope.

Requirements:

• The machine must be on a level surface.

• All tires must be properly inflated; refer to

Checking the Tire Pressure (page 48)

.

Figure 66

1.

Sharpen at original angle.

2.

Check the balance of the blade by putting it on a

blade balancer ( Figure 67

).

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 66

).

g000552

Leveling from Side to Side

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.

Set the height-of-cut lever to the middle position.

4.

Carefully rotate the blades so that they are all

side to side ( Figure 68

and

Figure 69 ).

1.

Blade

Figure 67

2.

Balancer

3.

Repeat this procedure until the blade is balanced.

g000553

53

g009682

Figure 68

Mower Decks with 2 Blades

1.

Blades side to side

2.

Sail area of the blade

3.

Outside cutting edges

4.

Measure from the tip of the blade to the flat surface here.

1.

Hanger bracket

2.

Side locking nut

Figure 70

3.

Rear nut g027588

9.

Check the side-to-side adjustments again.

Repeat this procedure until the measurements are correct.

10.

Continue leveling the mower deck by checking the front-to-rear blade slope; refer to

Adjusting the Front-to-Rear Blade Slope (page 54)

.

g005278

Figure 69

Mower Decks with 3 Blades

1.

Blades side to side

2.

Sail area of the blade

3.

Outside cutting edges

4.

Measure from the tip of the blade to the flat surface here.

5.

Measure between the outside cutting edges and the flat surface (

Figure 68

and

Figure 69 ).

Note: If both measurements are not within

5 mm (3/16 inch), an adjustment is required; continue with this procedure.

6.

Move to the left side of the machine.

7.

Loosen the side locking nut.

8.

Raise or lower the left side of the mower deck

by rotating the rear nut ( Figure 70 ).

Note: Rotate the rear nut clockwise to raise the mower deck; rotate the rear nut counter-clockwise to lower the mower deck

(

Figure 70

).

Adjusting the Front-to-Rear Blade

Slope

Check the front-to-rear blade level any time you install the mower. If the front of the mower is more than

7.9 mm (5/16 inch) lower than the rear of the mower, adjust the blade level using the following instructions:

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.

Set the height-of-cut lever to the middle position.

Note: Check and adjust the side-to-side blade level if you have not checked the setting; refer to

Leveling from Side to Side (page 53)

.

4.

Carefully rotate the blades so they are facing

front to rear ( Figure 71

and

Figure 72

).

54

g009658

Figure 71

Mower Decks with 2 Blades

1.

Blades front to rear

2.

Measure from the tip of the blade to the flat surface here.

g014634

1.

Adjusting rod

2.

Adjusting block

Figure 73

3.

Locknut g009659

Figure 72

Mower Decks with 3 Blades

1.

Blades front to rear 3.

Measure from the tip of the blade to the flat surface here.

2.

Outside cutting edges

7.

To raise the front of the mower, tighten the adjustment nut.

8.

To lower the front of the mower, loosen the adjustment nut.

9.

After adjustment, check the front-to-rear slope again, continue adjusting the nut until the front blade tip is 1.6 to 7.9 mm (1/16 to 5/16 inch) lower than the rear blade tip (

Figure 71

and

Figure 72 ).

10.

When the front-to-rear blade slope is correct check the side-to-side level of the mower again, refer to

Leveling from Side to Side (page 53)

.

5.

Measure from the tip of the front blade to the flat surface, and the tip of the rear blade to the flat surface (

Figure 71

and

Figure 72

).

Note: If the front blade tip is not 1.6 to 7.9 mm

(1/16 to 5/16 inch) lower than the rear blade tip, adjust the front locknut.

6.

To adjust the front-to-rear blade slope, rotate the adjustment nut in the front of the mower (

Figure

73 ).

Removing the Mower Deck

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.

Lower the height-of-cut lever to the lowest position.

4.

Loosen the bottom 2 bolts holding the mower-deck curtain to the mower deck. Refer to

Releasing the Mower-Deck Curtain (page 39)

.

5.

Remove the hairpin cotter from the front support rod, and remove the rod from the deck bracket

(

Figure 74

).

55

9.

Slide the mower deck out from underneath the machine.

Note: Retain all parts for future installation.

1.

Front support rod

2.

Locking nut

Figure 74

3.

Deck bracket

6.

Carefully lower the front of the mower deck to the ground.

7.

Lift the mower deck and hanger brackets clear of the rear lift rod and lower the mower carefully to the ground (

Figure 75 ).

g014635

Installing the Mower Deck

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.

Slide the mower under the machine.

4.

Lower the height-of-cut lever to the lowest position.

5.

Lift the rear of the mower deck and guide the

hanger brackets over the rear lift rod ( Figure 75

).

6.

Attach the front support rod to the mower deck with the clevis pin and hairpin cotter (

Figure 74

).

7.

Install the mower belt onto the engine pulley; refer to

Replacing the Mower-Deck Belt (page

49)

.

8.

Tighten the bottom 2 bolts for the mower-deck curtain to the mower deck; refer to

Releasing the Mower-Deck Curtain (page 39)

.

1.

Mower deck

2.

Hanger bracket

Figure 75

3.

Rear lift rod g005077

Replacing the Grass

Deflector

Service Interval: Before each use or daily—Inspect the grass deflector for damage.

WARNING

An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur.

Never operate the machine without the grass deflector, the discharge cover, or the grass-collection system in place.

1.

Remove the nut (3/8 inch) from the rod under

the mower ( Figure 76

).

8.

Slide the mower deck rearward to remove the mower belt from the engine pulley.

56

Figure 76

1.

Mower deck

2.

Grass deflector

3.

Grass-deflector bracket

4.

Rod

5.

Spring

6.

Nut (3/8 inch)

7.

Short standoff g005192

2.

Slide the rod out of the short stand-off, spring,

and grass deflector ( Figure 76

).

3.

Remove the damaged or worn grass deflector.

4.

Replace the grass deflector ( Figure 76 ).

5.

Slide the rod, straight end, through the rear grass deflector bracket.

6.

Place the spring on the rod, with end wires down, and between the grass deflector brackets.

7.

Slide the rod through the second grass-deflector

bracket ( Figure 76

).

8.

Insert the rod at the front of the grass deflector into the short standoff on the deck.

9.

Secure the rear end of the rod into the mower with a nut (3/8 inch) as shown in

Figure 76

.

Important: The grass deflector must be spring-loaded in the down position. Lift the deflector up to test that it snaps into the full-down position.

Cleaning

Washing the Underside of the Mower Deck

Service Interval: After each use—Clean the mower-deck housing.

Important: You can wash the machine with a mild detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, under the seat, around the engine, hydraulic pumps, and motors.

Wash the underside of the mower deck after each use to prevent grass buildup for improved mulch action and clipping dispersal.

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.

Attach the hose coupling to the end of the mower washout fitting, and turn the water on

high ( Figure 77

).

Note: Spread petroleum jelly on the washout fitting O-ring to make the coupling slide on easier and protect the O-ring.

1.

Washout fitting

2.

Hose

Figure 77

3.

O-ring

4.

Coupling g020098

4.

Lower the mower to the lowest height-of-cut.

5.

Sit on the seat and start the engine.

6.

Engage the blade-control switch and let the mower run for 1 to 3 minutes.

7.

Disengage the blade-control switch, shut off the engine, remove the key, and wait for all moving parts to stop.

57

8.

Turn the water off and remove the coupling from the washout fitting.

Note: If the mower is not clean after 1 washing, soak it and let it stand for 30 minutes. Then repeat the process.

9.

Run the mower again for 1 to 3 minutes to remove excess water.

WARNING

A broken or missing washout fitting could expose you and others to thrown objects or blade contact. Contact with a blade or thrown debris can cause injury or death.

• Replace broken or missing washout fitting immediately, before using machine again.

• Never put your hands or feet under the mower or through openings in the machine.

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.

Storage

Storage Safety

• Let the engine cool before storing the machine.

• Do not store the machine or fuel near flames or drain the fuel indoors.

Cleaning and Storage

1.

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.

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.

4.

Check the parking brake operation; refer to

Park

Position (page 16)

.

5.

Service the air cleaner; refer to

Servicing the Air

Cleaner (page 40)

.

6.

Grease the machine; refer to

Lubrication (page

39)

.

7.

Change the crankcase oil; refer to

Changing the

Engine Oil and Oil Filter (page 42)

.

8.

Check the tire pressure; refer to

Checking the

Tire Pressure (page 48)

.

9.

Charge the battery; refer to

Charging the Battery

(page 47)

.

10.

Scrape any heavy buildup of grass and dirt from the underside of the mower, then wash the mower with a garden hose.

Note: Run the machine with the blade-control switch (PTO) engaged and the engine at high idle for 2 to 5 minutes after washing.

11.

Check the condition of the blades; refer to

Servicing the Cutting Blades (page 51)

.

12.

Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows:

A.

Add a petroleum based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer. Do not use

58

an alcohol-based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times.

B.

Run the engine to distribute conditioned fuel through the fuel system (5 minutes).

C.

Shut off the engine, allow it to cool, and drain the fuel tank.

D.

Start the engine and run it until it stops.

E.

Dispose of fuel properly. Recycle the fuel according to local codes.

Important: Do not store stabilizer/conditioned fuel over

90 days.

13.

Remove and check the condition of the spark plug(s); refer to

Servicing the Spark Plug (page

44)

. With the spark plug(s) removed from the engine, pour 30 ml (2 tablespoons) of engine oil into the spark plug hole. Use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

14.

Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is damaged.

15.

Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.

16.

Store the machine in a clean, dry garage or storage area. Remove the key from the switch and keep it out of reach of children or other unauthorized users. Cover the machine to protect it and keep it clean.

Storing the Battery

1.

Fully charge the battery.

2.

Let the battery rest for 24 hours, then check the battery voltage.

Note: If the battery voltage is below 12.6 V, repeat steps

1

and

2 .

3.

Disconnect the cables from the battery.

4.

Check the voltage periodically to ensure that the voltage is 12.4 V or higher.

Note: If the battery voltage is below 12.4 V, repeat steps

1

and

2 .

Battery Storage Tips

• Store the battery in a cool, dry area in an upright position.

• Do not stack batteries directly on top of each other, unless they are in cartons.

• Do not stack more than 3 batteries (only 2 if the battery type is commercial).

• Test a wet battery every 4 to 6 months and charge it, if necessary.

• Always test and charge the battery before installation.

59

Troubleshooting

Problem

The fuel tank is showing signs of collapsing or the machine is frequently showing signs of running out of fuel.

The engine overheats.

Possible Cause Corrective Action

1. The air-cleaner paper element clogged.

1. Clean the paper element.

The starter does not crank.

The engine does not start, starts hard, or fails to keep running.

The engine loses power.

1. The engine load is excessive.

2. The oil level in the crankcase is low.

3. The cooling fins and air passages under the engine-blower housing are plugged.

4. The air cleaner is dirty.

1. Reduce the ground speed.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling fins and air passages.

4. Clean or replace the air-cleaner element.

5. Contact an Authorized Service Dealer 5. Dirt, water, or stale fuel is in the fuel system.

1. The blade-control switch is engaged.

2. The motion-control levers are not in the P ARK position.

3. The battery is dead.

4. The electrical connections are corroded or loose.

5. A fuse is blown.

6. A relay or switch is damaged.

1. Disengage the blade-control switch.

2. Move the motion-control levers outward to the P ARK position.

3. Charge the battery.

4. Check the electrical connections for good contact.

5. Replace the fuse.

6. Contact an Authorized Service Dealer.

1. The fuel tank is empty.

1. Fill the fuel tank.

2. The choke (if applicable) is not on.

3. The air cleaner is dirty.

4. The spark-plug wire(s) is loose or disconnected.

5. The spark plug(s) is pitted, fouled, or the gap is incorrect.

6. There is dirt in fuel filter.

7. Dirt, water, or stale fuel is in fuel system.

2. Move the choke lever to the O N position.

3. Clean or replace the air-cleaner element.

4. Install the wire(s) on the spark plug.

5. Install a new, correctly gapped spark plug(s).

6. Replace the fuel filter.

7. Contact an Authorized Service Dealer.

8. There is incorrect fuel in the fuel tank.

8. Drain the tank and replace the fuel with the proper type.

9. The oil level in the crankcase is low.

9. Add oil to the crankcase.

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 under the engine blower housing are plugged.

5. The spark plug(s) is pitted, fouled, or the gap is incorrect.

6. The fuel-tank vent is blocked.

7. There is dirt in the fuel filter.

2. Clean the air-cleaner element.

3. Add oil to the crankcase.

4. Remove the obstruction from the cooling fins and air passages.

5. Install a new, correctly gapped spark plug(s).

6. Contact an Authorized Service Dealer.

7. Replace the fuel filter.

8. Dirt, water, or stale fuel is in the fuel system.

8. Contact an Authorized Service Dealer.

9. There is incorrect fuel in the fuel tank.

9. Drain the tank and replace the fuel with the proper type.

60

Problem

The machine does not drive.

The machine vibrates abnormally.

The cutting height is uneven.

The blades do not rotate.

Possible Cause

1. The bypass valves are open.

2. The traction belts are worn, loose, or broken.

3. The traction belts are off the pulleys.

4. The transmission has failed.

1. The cutting blade(s) is/are bent or unbalanced.

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.

Corrective Action

1. Close the tow valves.

2. Contact an Authorized Service Dealer.

3. Contact an Authorized Service Dealer.

4. Contact an Authorized Service Dealer.

1. Install new cutting blade(s).

2. Tighten the blade mounting bolt.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

5. Contact an Authorized Service Dealer.

6. Contact an Authorized Service Dealer.

7. Contact an Authorized Service Dealer.

1. The blade(s) is not sharp.

2. A cutting blade(s) is/are bent.

3. The mower is not level.

1. Sharpen the blade(s).

2. Install a new cutting blade(s).

3. Level the mower from side-to-side and front-to-rear.

4. Adjust the anti-scalp wheel height.

4. An anti-scalp roller (if applicable) is not set correctly.

5. The underside of the mower deck is dirty.

6. The tire pressure is incorrect.

7. A blade spindle is bent.

5. Clean the underside of the mower deck.

6. Adjust the tire pressure.

7. Contact an Authorized Service Dealer.

1. The drive belt is worn, loose or broken.

1. Install a new drive belt.

2. The drive belt is off of the pulley.

2. Install the drive belt and check the adjusting shafts and belt guides for the correct position.

3. Contact an Authorized Service Dealer.

3. The power-takeoff (PTO) switch or

PTO clutch is faulty.

4. The mower belt is worn, loose, or broken.

4. Install a new mower belt.

61

Schematics

Electrical Diagram (Rev. A)

62 g028022

Notes:

EEA/UK Privacy Notice

Toro’s Use of Your Personal Information

The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company or dealer. Toro uses this information to fulfil contractual obligations - such as to register your warranty, process your warranty claim or to contact you in the event of a product recall - and for legitimate business purposes - such as to gauge customer satisfaction, improve our products or provide you with product information which may be of interest. Toro may share your information with our subsidiaries, affiliates, dealers or other business partners in connection these activities. We may also disclose personal information when required by law or in connection with the sale, purchase or merger of a business. We will never sell your personal information to any other company for marketing purposes.

Retention of your Personal Information

Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements. For more information about applicable retention periods please contact [email protected].

Toro’s Commitment to Security

Your personal information may be processed in the US or another country which may have less strict data protection laws than your country of residence.

Whenever we transfer your information outside of your country of residence, we will take legally required steps to ensure that appropriate safeguards are in place to protect your information and to make sure it is treated securely.

Access and Correction

You may have the right to correct or review your personal data, or object to or restrict the processing of your data. To do so, please contact us by email at [email protected]. If you have concerns about the way in which Toro has handled your information, we encourage you to raise this directly with us.

Please note that European residents have the right to complain to your Data Protection Authority.

374-0282 Rev C

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement

Table of contents