Operators manual
Form No. 3364-184 Rev B
Z580-D Z Master®
with a 132cm or 152cm TURBO FORCE®
Side Discharge Mower
Model No. 74264TE—Serial No. 310000001 and Up
Model No. 74265TE—Serial No. 310000001 and Up
To register your product or download an Operator's Manual or Parts Catalog at no charge, go to www.Toro.com.
Original Instructions (EN)
injury or death if you do not follow the recommended
precautions.
This product complies with all relevant European
directives, for details please see the separate product
specific Declaration of Conformity (DOC) sheet.
Introduction
Figure 2
1. Safety alert symbol
This rotary-blade, riding lawn mower is intended to
be used by residential homeowners or professional,
hired operators. It is designed primarily for cutting
grass on well-maintained lawns on residential
or commercial properties. It is not designed for
cutting brush or for agricultural uses.
This manual uses 2 other words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
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.
Contents
Introduction................................................................. 2
Safety ........................................................................... 4
Safe Operating Practices ....................................... 4
Toro Riding Mower Safety .................................... 5
Sound Pressure..................................................... 6
Sound Power ........................................................ 6
Vibration Level .................................................... 6
Slope Indicator..................................................... 7
Safety and Instructional Decals ............................. 8
Product Overview ...................................................... 15
Controls ............................................................. 15
Operation................................................................... 16
Adding Fuel ....................................................... 16
Biodiesel Ready .................................................. 17
Filling the Fuel Tank........................................... 17
Checking the Engine Oil Level............................ 17
Switching the Fuel Tanks .................................... 17
Using the Rollover Protection System
(ROPS) .......................................................... 18
Think Safety First ............................................... 19
Operating the Parking Brake ............................... 20
Starting and Stopping the Engine ........................ 20
Operating the Power Take Off (PTO) ................. 22
The Safety Interlock System................................ 22
Driving Forward or Backward............................. 23
Stopping the Machine......................................... 24
Adjusting the Height-of-Cut ............................... 24
Adjusting the Anti-Scalp Rollers ......................... 24
Adjusting the Flow Baffle ................................... 25
Positioning the Flow Baffle................................. 26
Using the Lift Assist Lever .................................. 26
Positioning the Seat ............................................ 27
Unlatching the Seat............................................. 27
Pushing the Machine by Hand............................. 27
Using the Side Discharge .................................... 28
Operating with the Overheat Sensor ................... 28
You may contact Toro directly at www.Toro.com for
product and 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.
Figure 1
1. Model and serial number location
Model No.
Serial No.
This manual identifies potential hazards and has
safety messages identified by the safety alert symbol
(Figure 2), which signals a hazard that may cause serious
© 2010—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Transporting Machines....................................... 28
Loading Machines .............................................. 29
Using the Z Stand®............................................ 29
Operating Tips ................................................... 31
Maintenance............................................................... 32
Recommended Maintenance Schedule(s) ................ 32
Lubrication............................................................. 33
Greasing and Lubrication ................................... 33
Greasing the Mower Deck and Belt
Idlers.............................................................. 33
Engine Maintenance............................................... 35
Servicing the Air Cleaner .................................... 35
Servicing the Engine Oil ..................................... 36
Fuel System Maintenance ....................................... 39
Servicing the Fuel Filter ...................................... 39
Servicing the Fuel Tank ...................................... 40
Electrical System Maintenance................................ 41
Servicing the Battery........................................... 41
Servicing the Fuses ............................................. 42
Drive System Maintenance ..................................... 43
Adjusting the Tracking........................................ 43
Checking the Tire Pressure ................................. 44
Checking the Wheel Hub Slotted Nut.................. 44
Adjusting the Caster Pivot Bearing ...................... 45
Servicing the Gear Box ....................................... 45
Adjusting the Electric Clutch .............................. 45
Cooling System Maintenance .................................. 47
Servicing the Cooling System.............................. 47
Brake Maintenance ................................................. 48
Adjusting the Parking Brake................................ 48
Belt Maintenance.................................................... 49
Inspecting the Belts ............................................ 49
Replacing the Mower Belt ................................... 49
Replacing the PTO Drive Belt............................. 49
Replacing the Pump Drive Belt ........................... 50
Replacing and Tensioning the Alternator
Belt ................................................................ 51
Controls System Maintenance................................. 52
Adjusting the Control Handle Neutral
Position.......................................................... 52
Hydraulic System Maintenance ............................... 53
Servicing the Hydraulic System ........................... 53
Setting the Hydraulic Pump Neutral
Position.......................................................... 55
Mower Deck Maintenance ...................................... 57
Leveling the Mower at Three Positions ................ 57
Servicing the Cutting Blades ............................... 58
Replacing the Grass Deflector............................. 60
Cleaning ................................................................. 61
Cleaning Under the Mower ................................. 61
Waste Disposal ................................................... 61
Storage....................................................................... 62
Cleaning and Storage .......................................... 62
Troubleshooting......................................................... 63
Schematics ................................................................. 65
3
Preparation
Safety
• While mowing, always wear substantial footwear and
long trousers. Do not operate the equipment when
barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment
is to be used and remove all objects which may be
thrown by the machine.
• Warning–Fuel is highly flammable.
– Store fuel in containers specifically designed for
this purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never
remove the cap of the fuel tank or add fuel while
the engine is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the
engine but move the machine away from the
area of spillage and avoid creating any source of
ignition until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
• Replace faulty silencers.
• Before using, always visually inspect to see that the
blades, blade bolts and cutter assembly are not worn
or damaged. Replace worn or damaged blades and
bolts in sets to preserve balance.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
This machine meets or exceeds European Standards in
effect at the time of production. However, improper
use or maintenance by the operator or owner can
result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER-"personal safety
instruction." Failure to comply with the instruction may
result in personal injury or death.
Safe Operating Practices
The following instructions are from the CEN standard
EN 836:1997.
This product is capable of amputating hands and
feet and throwing objects. Always follow all safety
instructions to avoid serious injury or death.
Training
• Read the instructions carefully. Be familiar with the
controls and the proper use of the equipment.
• Never allow children or people unfamiliar with these
instructions to use the lawnmower. Local regulations
can restrict the age of the operator.
• Never mow while people, especially children, or pets
are nearby.
• Keep in mind that the operator or user is responsible
for accidents or hazards occurring to other people or
their property.
• Do not carry passengers.
• All drivers should seek and obtain professional
and practical instruction. Such instruction should
emphasize:
– the need for care and concentration when
working with ride-on machines;
– control of a ride-on machine sliding on a slope
will not be regained by the application of the
control levers. The main reasons for loss of
control are:
◊ insufficient wheel grip, especially on wet
grass;
◊ being driven too fast;
◊ inadequate braking;
◊ the type of machine is unsuitable for its task;
◊ lack of awareness of the effect of ground
conditions, especially slopes;
◊ incorrect hitching and load distribution.
Operation
• 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.
• Be alert, slow down and use caution when making
turns. Look behind and to the side before changing
directions.
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches and shift into neutral.
• Do not use on slopes greater than 15 degrees.
• Remember there is no such thing as a safe slope.
Travel on grass slopes requires particular care. To
guard against overturning:
– - do not stop or start suddenly when on a slope;
– - use slow speeds on slopes and during tight
turns;
4
•
•
•
•
•
•
•
•
•
•
•
Maintenance and Storage
– - stay alert for humps and hollows and other
hidden hazards;
Use care when pulling loads or using heavy
equipment.
– - Use only approved drawbar hitch points.
– - Limit loads to those you can safely control.
– - Do not turn sharply. Use care when reversing.
Watch out for traffic when crossing or near roadways.
Stop the blades rotating before crossing surfaces
other than grass.
When using any attachments, never direct discharge
of material toward bystanders nor allow anyone near
the machine while in operation.
Never operate the machine with damaged guards or
without safety protective devices in place.
Do not change the engine governor settings or
overspeed the engine. Operating the engine at
excessive speed can increase the hazard of personal
injury.
Before leaving the operator’s position:
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
Disengage drive to attachments, stop the engine,
and disconnect the spark plug wire(s) or remove the
ignition key
– before clearing blockages or unclogging chute;
– before checking, cleaning or working on the
lawnmower;
– after striking a foreign object. Inspect the
lawnmower for damage and make repairs before
restarting and operating the equipment; if the
machine starts to vibrate abnormally (check
immediately).
Disengage drive to attachments when transporting
or not in use.
Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher;
– before making height adjustment unless
adjustment can be made from the operator’s
position.
Reduce the throttle setting during engine run-out
and, if the engine is provided with a shut-off valve,
turn the fuel off at the conclusion of mowing.
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
• Never store the equipment with fuel in the tank
inside a building where fumes can reach an open
flame or spark.
• Allow the engine to cool before storing in any
enclosure.
• To reduce the fire hazard, keep the engine, silencer,
battery compartment and fuel storage area free of
grass, leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Replace worn or damaged parts for safety.
• If the fuel tank has to be drained, this should be
done outdoors.
• On multi-bladed machines, take care as rotating one
blade can cause other blades to rotate.
• When machine is to be parked, stored or left
unattended, lower the cutting means unless a positive
mechanical lock is used.
Toro Riding Mower Safety
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN standard.
• Engine exhaust contains carbon monoxide, which is
an odorless, deadly poison that can kill you. Do not
run engine indoors or in an enclosed area.
• Keep hands, feet, hair and loose clothing away from
attachment discharge area, underside of mower and
any moving parts while engine is running.
• Do not touch equipment or attachment parts which
may be hot from operation. Allow to cool before
attempting to maintain, adjust, or service.
• Battery acid is poisonous and can cause burns. Avoid
contact with skin, eyes and clothing. Protect your
face, eyes, and clothing when working with a battery.
• Battery gases can explode. Keep cigarettes, sparks
and flames away from battery.
• Use only genuine Toro replacement parts to ensure
that original standards are maintained.
• Use only Toro-approved attachments. Warranty may
be voided if used with unapproved attachments.
Slope Operation
• Do not mow slopes greater than 15 degrees.
5
Measured vibration level for right hand = 2.7 m/s2
• Do not mow near drop-offs, ditches, steep banks
or water. Wheels dropping over edges can cause
rollovers, which may result in serious injury, death
or drowning.
• Do not mow slopes when grass is wet. Slippery
conditions reduce traction and could cause sliding
and loss of control.
• Do not make sudden turns or rapid speed changes.
• Use a walk behind mower and/or a hand trimmer
near drop-offs, ditches, steep banks or water.
• Reduce speed and use extreme caution on slopes.
• Remove or mark obstacles such as rocks, tree limbs,
etc. from the mowing area. Tall grass can hide
obstacles.
• Watch for ditches, holes, rocks, dips, and rises that
change the operating angle, as rough terrain could
overturn the machine.
• Avoid sudden starts when mowing uphill because
the mower may tip backwards.
• Be aware that loss of traction may occur going
downhill. Weight transfer to the front wheels may
cause drive wheels to slip and cause loss of braking
and steering.
• Always avoid sudden starting or stopping on a
slope. If tires lose traction, disengage the blades and
proceed slowly off the slope.
• Follow the manufacturer’s recommendations for
wheel weights or counterweights to improve stability.
• Use extreme care with grass catchers or other
attachments. These can change the stability of the
machine and cause loss of control.
Measured vibration level for left hand = 3.3 m/s2
Uncertainty Value (K) = 1.7 m/s2
Measured values were determined according to the
procedures outlined in EN 836.
Whole Body
Measured vibration level = 0.75 m/s2
Uncertainty Value (K) = 0.38 m/s2
Measured values were determined according to the
procedures outlined in EN 836.
Sound Pressure
This unit has a sound pressure level at the operator’s
ear of 92 dBA, which includes an Uncertainty Value (K)
of 1 dBA.
The sound pressure level was determined according to
the procedures outlined in EN 836.
Sound Power
This unit has a guaranteed sound power level of 105
dBA, which includes an Uncertainty Value (K) of 1 dBA.
The sound power level was determined according to the
procedures outlined in ISO 11094.
Vibration Level
Hand-Arm
6
Slope Indicator
G011841
Figure 3
This page may be copied for personal use.
1. The maximum slope you can safely 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.
7
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 lost.
98-1977
1. Entanglement hazard, belt—stay away from moving parts.
58-6520
1. Grease
98-4387
1. Warning—wear hearing protection.
93-7010
1. Thrown object hazard—
2. Thrown object hazard, mower—keep the deflector in place.
3. Cutting/dismemberment of hand or foot—stay away from
moving parts.
99-8939
1. Read the Operator’s
Manual.
93-7818
1. Warning—read the Operator’s Manual for instructions on
torquing the blade bolt/nut to 115-149 N-m (85-110 ft-lb).
2. Height of cut
93-8069
1. Hot surface/burn hazard—stay a safe distance from the
hot surface.
8
3. Remove the ignition key
and read the instructions
before servicing or
performing maintenance.
107-2131
1. Hydraulic oil level
2. Warning—do not touch
the hot surface.
104-2449
107-1866
1. Sliding and loss of control hazard and tipping hazard,
drop-offs—do not operate the machine near drop-offs,
slopes greater than 15 degrees, or water; keep a safe
distance from drop-offs; do not turn sharply while traveling
fast, instead, slow down and turn gradually; if the roll bar
is raised, wear the seat belt; if the roll bar is lowered, do
not wear the seat belt.
107-3069
1. Warning–there is no rollover protection when the roll bar is
down.
2. To avoid injury or death from a rollover accident, keep the
roll bar in the raised and locked position and wear the seat
belt. Lower the roll bar only when absolutely necessary; do
not wear the the seat belt when the roll bar is down.
3. Read the Operator’s Manual; drive slowly and carefully.
107-2114
9
107-3968
1. Disengage
2. Engage
3. Parking brake
107-3969
1. Warning—read the Operator’s Manual.
2. Crushing hazard, mower—engage the parking brake, stop
the engine, and remove the ignition key before working
under the mower.
107-3961
1. Height of cut in millimeters
107-7719
1. Cutting/dismemberment hazard, fan and entanglement
hazard, belt—stay away from moving parts.
2. Before starting the engine, clean grass and debris from the
mower belt and pulleys, insert the ignition key, and start
the engine.
107-3962
1. Height of cut in millimeters
108-5955
10
108-5957
110-2068
1. Read the Operator’s Manual.
110-3842
108-5981
109-7949
110–0806
110-3851
1. Remove the ignition key and read the instructions before
servicing or performing maintenance.
110-2067
11
110-3852
1. Remove the ignition key
and read the instructions
before servicing or
performing maintenance.
2. Continuous tone signals
the user that engine is
overheating.
117-0912
1. Push to engage
2. Engine—preheat
3. Rear the Operator’s
Manual.
110-3853
1. Cutting/dismemberment
hazard, fan and
entanglement hazard,
belt.
4. Fast
5. Continuous variable
setting
6. Slow
2. Remove the ignition key
and read the instructions
before servicing or
performing maintenance.
119–0397
112-8651
1.
2.
3.
4.
5.
6.
Interval
Power Take-off (PTO)
Parking brake
Neutral
Operator presence switch
Battery
119–0398
Manufacturer’s Mark
1. Indicates the blade is identified as a part from the original
machine manufacturer.
114-9600
1. Read the Operator’s Manual.
12
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 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.
107-3963
1. Cutting/dismemberment
hazard, mower blade—do
not carry passengers and
keep bystanders away.
3. Thrown object
hazard—keep bystanders
a safe distance from the
machine and keep the
deflector in place.
2. Cutting/dismemberment
hazard of hand or foot,
mower blade—remove
the ignition key and read
the instructions before
servicing or performing
maintenance; stay away
from moving parts.
13
4. Before starting the engine,
clean grass and debris from
the mower belt and pulleys,
insert the ignition key, and
start the engine.
107-3964
1. Warning—do not use drugs or alcohol.
2. Warning—read the Operator’s Manual
and receive training.
3. Warning—engage the parking brake,
stop the engine, and remove the
ignition key before leaving the
machine.
4. Warning—wear hearing protection.
5. Read the Operator’s Manual.
107-9309
1. Warning—read the Operator’s Manual for information on
charging the battery; contains lead; do not discard.
2. Read the Operator’s Manual.
110-0820
1. Fast
2. Slow
5. Warning—read the Operator’s Manual.
6. Poison and caustic liquid/chemical burn hazard—keep
children a safe distance from the battery.
7. Explosion hazard—no fire, open flames, or smoking; avoid
sparks.
8. To unlock the traction drive, turn the by-pass valve 1 complete
revolution counterclockwise using a 5/8 inch or 16 mm
wrench.
3. Neutral
4. Reverse
14
Hour Meter
Product Overview
The hour meter records the number of hours the engine
has operated. It operates when the engine is running.
Use these times for scheduling regular maintenance
(Figure 5).
Safety Interlock Indicators
There are symbols on the hour meter and they indicate
with a black triangle that the interlock component is in
the correct position (Figure 6).
Battery Indicator Light
When the ignition key is initially turned to the Run
position for a few seconds, the battery voltage will be
displayed in the area where the hours are normally
displayed.
The battery light turns on when the ignition is turned
on and when the charge is below the correct operating
level (Figure 6).
Figure 4
1.
2.
3.
4.
5.
Z Stand©
Height-of-cut lever
Motion control lever
Seat belt
Roll bar
6.
7.
8.
9.
Fuel cap (both sides)
Parking brake lever
Mower deck
Caster wheel
Controls
Become familiar with all the controls before you start the
engine and operate the machine (Figure 4 and Figure 5).
Figure 6
1. Safety interlock symbols
2. Hour meter
3. Battery light
Throttle Control
The throttle control is variable between Fast and Slow.
Blade Control Switch (PTO)
The blade control switch (PTO) is used to engage the
electric clutch to drive the mower blades with the motion
control levers in the center, un-locked position. Pull the
switch up to engage the blades and release. To disengage
the blades, push the blade control switch (PTO) down.
Figure 5
1.
2.
3.
4.
5.
Hour meter
Ignition switch
Fuel selector valve
Audible alarm
Glow plug switch
6.
7.
8.
9.
Glow plug light
Engine Temperature light
Throttle control
PTO Switch
Neutral Lock Position
The neutral lock position is used with the safety interlock
system and to determine neutral position.
15
Ignition Switch
Operation
This switch is used to start the mower engine and has
three positions: Start, Run and Off.
Note: Determine the left and right sides of the
machine from the normal operating position.
Glow Plug Light
Adding Fuel
The glow plug indicator light turns on when the glow
plug button is engaged (Figure 5).
The engine runs on clean, fresh diesel fuel with
a minimum octane rating of 40. Purchase fuel in
quantities that can be used within 30 days to ensure
fuel freshness.
Glow Plug Switch
This switch activates the glow plugs and is indicated by
the glow plug light. Hold down the glow plug switch for
10 seconds prior to starting.
Use summer grade diesel fuel (No. 2-D) at temperatures
above 20° F (-7° C) and winter grade diesel fuel (No.
1-D or No. 1-D/2-D blend) below 20° F (-7° C). Use of
winter grade diesel fuel at lower temperatures provides
lower flash point and pour point characteristics,
therefore easing startability and lessening chances
of chemical separation of the fuel due to lower
temperatures (wax appearance, which may plug filters).
Temperature Light
The temperature light comes on when the engine is over
heating (Figure 5).
Audible Alarm
Use of summer grade diesel fuel above 20° F (-7° C) will
contribute toward longer life of the pump components.
This machine has an audible alarm that alerts the user
to turn off the engine or engine damage can occur from
over heating. Refer to Servicing the Cooling System in
Cooling System Maintenance (page 47).
Important: Do not use kerosene or gasoline
instead of diesel fuel. Failure to observe this
caution will damage the engine.
WARNING
Fuel Selector Valve
Fuel is harmful or fatal if swallowed. Long-term
exposure to vapors can cause serious injury and
illness.
The fuel selector valve is located behind the seat.
Close the fuel selector valve when transporting or
storing mower.
• Avoid prolonged breathing of vapors.
Move the selector valve to the lefthand (LH) or
righthand (RH) position for operation.
• Keep face away from nozzle and gas tank or
conditioner opening.
• Keep gas away from eyes and skin.
Attachments/Accessories
A selection of Toro approved attachments and
accessories are available for use with the machine to
enhance and expand its capabilities. Contact your
Authorized Service Dealer or Distributor or go to
www.Toro.com for a list of all approved attachments
and accessories.
16
• Use B5 (biodiesel contend of 5%) or lesser blend
in cold weather.
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.
• Fill the fuel tank outdoors on level ground, in
an open area, when the engine is cold. Wipe
up any fuel that spills.
• Never fill the fuel tank 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 (if
equipped).
• Never smoke when handling fuel, and stay
away from an open flame or where fuel fumes
may be ignited by a spark.
• Store fuel in an approved container and keep it
out of the reach of children. Never buy more
than a 30-day supply of fuel.
• Always place fuel containers on the ground
away from your vehicle before filling.
• Do not fill fuel containers inside a vehicle or on
a truck or trailer bed because interior carpets
or plastic truck bed liners may insulate the
container and slow the loss of any static charge.
• When practical, remove gas-powered
equipment from the truck or trailer and refuel
the equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a fuel dispenser
nozzle.
• If a fuel dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
• Monitor seals, hoses, gaskets in contact with fuel as
they may be degrade over time.
• Fuel filter plugging maybe expected for a time after
converting to biodiesel blends.
• Contact your distributor if you wish for more
information on biodiesel.
Filling the Fuel Tank
Note: 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 the gasoline to expand.
1. Shut the engine off and set the parking brake.
2. Clean around each fuel tank cap and remove the
cap. Fill the fuel tank to the bottom of the filler
neck. This space in the tank allows the fuel to
expand. Do not fill the fuel tank completely full.
3. Install the fuel tank cap securely. Wipe up any fuel
that may have spilled.
4. If possible, fill the fuel tank after each use. This will
minimize possible buildup of condensation inside
the fuel tank.
Checking the Engine Oil Level
Before you start the engine and use the machine, check
the oil level in the engine crankcase; refer to Checking
Oil Level in Engine Maintenance (page 35)
Switching the Fuel Tanks
Important: Do not run the machine out of fuel.
This may cause engine damage and require the
fuel system to be checked.
The fuel selector valve is located behind the left side
of the seat.
Biodiesel Ready
This machine can also use a biodiesel blended fuel
of up to B20 (20% biodiesel, 80% petrodiesel). The
petrodiesel portion should be low or ultra low sulfur.
The unit has two fuel tanks. One tank is on the left
side and one on the right side. Each tank connects to
the fuel selector valve. From there a common fuel line
leads to the engine (Figure 7).
Observe the following precautions:
• The biodiesel portion of the fuel meet specification
ASTM D6751 or EN14214.
• The blended fuel composition should meet ASTM
D975 or EN590.
• Painted surfaces may be damaged by biodiesel
blends.
To use the left side fuel tank rotate the fuel selector
valve to the LH, lefthand location. To use the right
side fuel tank rotate the fuel selector valve to the RH,
righthand location (Figure 7)
Close the fuel selector valve before transporting or
storing machine.
17
Important: Lower the roll bar only when
absolutely necessary.
1. Remove the hairpin cotter pins and remove the two
pins (Figure 9).
2. Lower the roll bar to the down position. There are
two down positions. See Figure 8 for the positions.
3. Install the two pins and secure them with the
hairpin cotter pins (Figure 9).
Figure 7
1. Left side fuel tank
Figure 8
2. Fuel selector valve
1. Full down position
Using the Rollover Protection
System (ROPS)
2. Down position with bagger
installed
Important: Ensure that the rear part of the
seat is secured with the seat latch.
4. To raise the roll bar, remove the hairpin cotter pins
and remove the two pins (Figure 9).
WARNING
To avoid injury or death from rollover: keep the
roll bar in the raised locked position and use the
seat belt.
5. Raise the roll bar to the upright position and install
the two pins and secure them with the hairpin cotter
pins (Figure 9).
Ensure that the rear part of the seat is secured with
the seat latch.
Important: Always use the seat belt with the
roll bar in the raised position.
WARNING
There is no rollover protection when the roll bar
is in the down position.
• Lower the roll bar only when absolutely
necessary.
• Do not wear the seat belt when the roll bar is
in the down position.
• Drive slowly and carefully.
• Raise the roll bar as soon as clearance permits.
• Check carefully for overhead clearances (i.e.
branches, doorways, electrical wires) before
driving under any objects and do not contact
them.
18
1
2
3
Figure 10
1. Safe Zone-use the
Z Master here on slopes
less than 15 degrees or
flat areas.
2. Use walk behind mower
and/or hand trimmer near
drop-offs and water.
4
G004955
Figure 9
1. Roll bar
2. Raised position
3. Water
3. Pin
4. Hairpin cotter pin
CAUTION
This machine produces sound levels in excess of
85 dBA at the operators ear and can cause hearing
loss through extended periods of exposure.
Think Safety First
Please read all safety instructions and symbols in the
safety section. Knowing this information could help
you or bystanders avoid injury.
Wear hearing protection when operating this
machine.
DANGER
Wear protective equipment for your eyes, ears, feet, and
head when using this machine.
Operating on wet grass or steep slopes can cause
sliding and loss of control.
Wheels dropping over edges can cause rollovers,
which may result in serious injury, death or
drowning.
There is no rollover protection when the roll bar
is down.
Always keep the roll bar in the raised and locked
position and use the seat belt.
Read and follow the rollover protection instructions
and warnings.
To avoid loss of control and possibility of rollover:
• Do not operate near drop-offs or near water.
• Do not operate on slopes greater than
15 degrees.
• Reduce speed and use extreme caution on
slopes.
• Avoid sudden turns or rapid speed changes.
19
Figure 11
1. Warning— wear hearing protection
Operating the Parking Brake
Always set the parking brake when you stop the
machine or leave it unattended.
Figure 12
1. Parking brake-ON
2. Parking brake-OFF
3. Brake Stop
Setting the Parking Brake
1. Move the motion control levers (Figure 18) out to
the neutral lock position.
Starting and Stopping the
Engine
2. Pull up and back on the parking brake lever to set
the parking brake (Figure 12). The parking brake
lever should stay firmly in the engaged position.
Starting the Engine in Normal Weather
WARNING
1. Raise the ROPS up and lock into place, sit on the
seat and fasten the seat belt.
Parking brake may not hold machine parked
on a slope and could cause personal injury or
property damage.
2. Move the motion controls to the neutral locked
position.
Do not park on slopes unless wheels are
chocked or blocked
3. Set the parking brake; refer to Setting the Parking
Brake.
Releasing the Parking Brake
4. Move the PTO (power take off) switch to the off
position (Figure 13).
Push forward and down on the parking brake lever
to release the parking brake (Figure 12). The parking
brake is disengaged and the lever will rest against the
brake stop.
5. Move the throttle lever to the middle position
(Figure 15).
6. Turn the ignition key clockwise to the run position
(Figure 14).
7. Push the glow plug switch for 10 seconds. The light
will turn on.
8. Release the switch after 10 seconds. The light will
turn off.
20
Figure 15
1. Throttle—fast
Starting the Engine in Cold Weather
(Below 23°F or -5°C)
Figure 13
1.
2.
3.
4.
Hour meter
Ignition switch
Glow plug switch
Glow plug light
2. Throttle—slow
5. Engine Temperature light
6. Throttle control
7. PTO Switch
Note: Use the correct engine oil for the starting
temperature. Refer to Servicing the Engine Oil in
Engine Maintenance (page 35).
1. Start the engine with the throttle in the Fast
position.
9. Turn the key to the start position and the glow plug
indicator light will come back on. When the engine
starts, release the key (Figure 14).
2. Turn the ignition key clockwise to the run position
(Figure 14).
Important: Use starting cycles of no more than
30 seconds per minute to avoid overheating the
starter motor.
3. Push the glow plug switch for 10 to 15 seconds.
The light will turn on.
10. If the engine does not start immediately, move the
throttle control to fast and turn the key to the start
position.
4. Release the switch after 10 to 15 seconds. The light
will turn off.
5. Turn the key to the start position and the glow plug
indicator light will come back on. When the engine
starts, release the key.
Note: Additional starting cycles may be required
when starting the engine for the first time after the
fuel system has been completely without fuel.
Important: Use starting cycles of no more than
30 seconds per minute to avoid overheating the
starter motor.
Note: Do not use fuel left over from the summer.
Use only fresh winter grade diesel fuel.
Stopping the Engine
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake (Figure 16 ).
Figure 14
1. Ignition switch
2. Off
2. Move the throttle lever midway between the slow
and fast positions (Figure 15 ).
3. Run
4. Start
3. Let the engine idle for 60 seconds.
21
4. Turn the ignition key to the off position (Figure 14).
Wait for all moving parts to stop before leaving the
operating position.
5. Remove the key to prevent possibility of someone
accidentally starting the machine before transporting
or storing machine.
6. Close the fuel selector valve before transporting or
storing the machine.
Important: Make sure that the fuel selector
valve is closed before transporting or storing
the machine, as fuel leakage may occur. Set the
parking brake before transporting.
Figure 16
1. PTO-On
Important: Make sure to remove the key as
the fuel pump may run and cause the battery
to lose charge.
2. PTO-Off
Disengaging the PTO
CAUTION
To disengage, push the PTO switch to the off position
(Figure 16).
Children or bystanders may be injured if they
move or attempt to operate the tractor while it
is unattended.
The Safety Interlock System
Always remove the ignition key and set the
parking brake when leaving the machine
unattended, even if just for a few minutes.
CAUTION
If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.
Operating the Power Take Off
(PTO)
• Do not tamper with the interlock switches.
• Check the operation of the interlock switches
daily and replace any damaged switches before
operating the machine.
The power take off (PTO) switch starts and stops the
mower blades and any powered attachments.
Engaging the PTO
Understanding the Safety Interlock
System
1. If the engine is cold, allow the engine to warm up 5
to 10 minutes before engaging the PTO.
The safety interlock system is designed to prevent the
engine from starting unless:
2. While seated in the seat, release the pressure on the
traction control levers and place in neutral.
• The parking brake is engaged.
3. Place the throttle in the fast position.
• The power take off (PTO) is disengaged.
Note: Engaging the PTO with the throttle at the
half or less position will cause excessive wear to the
drive belts.
• The motion control levers are in the neutral locked
position
The safety interlock system also is designed to stop the
engine when the traction controls are moved from the
locked position with the parking brake engaged or if
you rise from the seat when the PTO is engaged.
4. Pull out on the power take off (PTO) switch to
engage it (Figure 16).
The hour meter has symbols to notify the user when the
interlock component is in the correct position. When
the component is in the correct position, a triangle will
light up in the corresponding square.
22
the throttle control in the fast position for best
performance. Always operate in the full throttle
position when mowing.
CAUTION
Machine can spin very rapidly. Operator may lose
control of machine and cause personal injury or
damage to machine.
• Use caution when making turns.
Figure 17
• Slow the machine down before making sharp
turns.
1. Triangles light up when the interlock components are in the
correct position
Driving Forward
Testing the Safety Interlock System
1. Release the parking brake; refer to Releasing the
Parking Brake in Operation.
Service Interval: Before each use or daily
2. Move the levers to the center, un-locked position.
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.
3. To go forward, slowly push the motion control
levers forward (Figure 18).
Note: The engine will kill if the traction control
levers are moved with the parking brake engaged.
1. Sitting on the seat, engage the parking brake and
move the PTO to on. Try starting the engine; the
engine should not crank.
To go straight, apply equal pressure to both motion
control levers (Figure 18).
2. Sitting on the seat, engage the parking brake and
move the PTO to off. Move either motion control
lever (out of neutral locked position). Try starting
the engine; the engine should not crank. Repeat for
other control lever.
To turn, move the motion control lever toward
neutral in the direction you want to turn (Figure 18).
The farther you move the traction control levers in
either direction, the faster the machine will move in
that direction.
3. Sitting on the seat, engage the parking brake,
move the PTO switch to off and move the motion
control levers to neutral lock position. Now start
the engine. While the engine is running, release
the parking brake, engage the PTO and rise slightly
from the seat; the engine should stop.
To stop, pull the motion control levers to the neutral
position.
4. Sitting on the seat, engage the parking brake, move
the PTO switch to off and move the motion control
levers to neutral lock position. Now start the engine.
While the engine is running, center either motion
control and move (forward or reverse); the engine
should stop. Repeat for other motion control.
5. Sitting on the seat, disengage the parking brake,
move the PTO switch to off and move the motion
control levers to neutral lock position. Try starting
the engine; the engine should not crank.
Driving Forward or Backward
The throttle control regulates the engine speed as
measured in rpm (revolutions per minute). Place
23
CAUTION
Children or bystanders may be injured if they
move or attempt to operate the tractor while it is
unattended.
Always remove the ignition key and set the parking
brake when leaving the machine unattended, even
if just for a few minutes.
Adjusting the Height-of-Cut
The height-of-cut is adjusted from 1-1/2 to 5 inch
(38 to 127 mm) in 1/4 inch (6 mm) increments by
relocating the pin into different hole locations.
1. Raise the height-of-cut lever to the transport
position (also the 5 inch (127 mm) cutting height
position) (Figure 19).
Figure 18
1. Motion control
lever-neutral lock position
2. Center un-lock position
3. Forward
4. Backward
Driving Backward
Figure 19
1. Move the levers to the center, un-locked position.
1. Height of cut lever
2. To go backward, slowly pull the motion control
levers rearward (Figure 18).
2. Pin
2. To adjust, remove the pin from the height-of-cut
bracket (Figure 19).
3. Select a hole in the height-of-cut bracket
corresponding to the height-of-cut desired and,
insert the pin (Figure 19).
4. Move the lever to the selected height.
To go straight, apply equal pressure to both motion
control levers (Figure 18).
To turn, release pressure on the motion control lever
toward the direction you want to turn (Figure 18).
To stop, push the motion control levers to the
neutral position.
Adjusting the Anti-Scalp
Rollers
Stopping the Machine
Whenever you change the height-of-cut, it is
recommended to adjust the height of the anti-scalp
rollers.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set the
parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
To stop the machine, move the traction control levers
to neutral and move to locked position, disengage the
power take off (PTO), and turn the ignition key to off.
Set the parking brake when you leave the machine; refer
to Setting the Parking Brake in Operation. Remember
to remove the key from the ignition switch.
24
3. After adjusting the height-of-cut, adjust the rollers
by removing the flange nut, bushing, spacer, and
bolt (Figure 20 , Figure 21 and Figure 22 ).
Note: The two middle rollers will not have a spacer
(Figure 21).
4. Select a hole so the anti-scalp roller is positioned to
the nearest corresponding height-of-cut desired.
5. Install the flange nut bushing, spacer, and bolt.
Torque to 40-45 ft-lb (54-61 N-m) (Figure 20 ,
Figure 21 and Figure 22 ).
Figure 22
6. Repeat this adjustment on the other anti-scalp
rollers.
1. Anti-scalp roller
2. Spacer
3. Bushing
4. Flange Nut
5. Bolt
Adjusting the Flow Baffle
The mower discharge flow can be adjusted for different
types of mowing conditions. Position the cam locks
and baffle to give the best quality of cut.
1. Disengage the PTO, move the motion control
levers to the neutral locked position and set the
parking brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. To adjust the cam locks, swing the lever up to
loosen the cam lock (Figure 23).
4. Adjust the baffle and cam locks in the slots to the
desired discharge flow.
5. Swing the lever back over to tighten the baffle and
cam locks (Figure 23).
6. If the cams do not lock the baffle into place or it is
too tight, loosen the lever and then rotate the cam
lock. Adjust the cam lock until the desired locking
pressure is achieved.
Figure 20
1. Anti-scalp roller
2. Spacer
3. Bushing
4. Flange Nut
5. Bolt
Figure 21
1. Anti-scalp roller
2. Bushing
3. Flange Nut
4. Bolt
Figure 23
1. Cam lock
2. Lever
25
3. Rotate cam to increase or
decrease locking pressure
4. Slot
Positioning the Flow Baffle
Position C
The following figures are only recommendations for
use. Adjustments will vary by grass type, moisture
content, and height of grass.
This is the full open position. The suggested use for
this position is as follows.
Note: If the engine power draws down and the mower
ground speed is the same, open up the baffle.
• Use in wet conditions.
Position A
• Allows increased ground speed in heavy conditions.
• Use in tall, dense grass mowing conditions.
• Lowers the engine power consumption.
• This position is similar to the benefits of the Toro
SFS mower.
This is the full rear position. The suggested use for this
position is a follows (Figure 24).
• Use for short, light grass mowing conditions.
• Use in dry conditions.
• For smaller grass clippings.
• Propels grass clippings farther away from the
mower.
Figure 26
Figure 24
Using the Lift Assist Lever
Position B
The lift assist lever is used along with the height-of-cut
lever for raising the mower deck. This allows for easier
raising of the mower deck.
Use this position when bagging.
1. Place your foot onto lift assist lever.
2. Press on the lift assist lever while pulling up on the
height-of-cut lever (Figure 27).
Figure 27
Figure 25
26
Positioning the Seat
Changing the Seat Position
The seat can move forward and backward. Position the
seat where you have the best control of the machine
and are most comfortable.
1. To adjust, move the lever sideways to unlock seat
(Figure 28).
2. Slide the seat to the desired position and release the
lever to lock it in position.
g012487
Changing the Seat Suspension
Figure 29
The seat can be adjusted to provide a smooth and
comfortable ride. Position the seat where you are most
comfortable.
1. Back rest knob
To adjust, turn the knob in front either direction to
provide the best comfort (Figure 28).
Unlatching the Seat
2. Rightside arm rest
1. Move the seat to the most rearward position. This
will prevent interference when the seat is raised.
2. Push the seat latch rearward to unlatch the seat.
3. Raise the seat up. This will allow access to the
machine under the seat (Figure 30).
g012486
Figure 28
1. Seat suspension knob
2. Seat position lever
Figure 30
Changing the Back Position
1. Seat latch
2. Fuel cap
The back of the seat can be adjusted to provide a
comfortable ride. Position the back of the seat where it
is most comfortable.
3. Seat
Pushing the Machine by Hand
To adjust, turn the knob, under the rightside arm rest, in
either direction to provide the best comfort (Figure 29).
Important: Always push the machine by hand.
Never tow the machine because hydraulic damage
may occur.
Pushing the Machine
1. Disengage the power take off (PTO) and turn the
ignition key to off. Move the levers to neutral locked
position and apply parking brake. Remove the key.
27
2. Rotate the by-pass valves counterclockwise 1 turn
to push. This allows hydraulic fluid to by-pass the
pump enabling the wheels to turn (Figure 31).
DANGER
Without the grass deflector, discharge cover, or
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.
Important: Do not rotate by-pass valves more
than 1 turn. This prevents valves from coming
out of the body and causing fluid to run out.
3. Disengage parking brake before pushing.
Rotate the by-pass valves clockwise 1 turn to operate
machine (Figure 31).
• Never remove the grass deflector from the
mower because the grass deflector routes
material down toward the turf. If the
grass deflector is ever damaged, replace it
immediately.
Note: Do not over tighten the by-pass valves.
• Never put your hands or feet under the mower.
The machine will not drive unless by-pass valves are
turned in.
• Never try to clear the discharge area or mower
blades unless you move the power take off
(PTO) to the off position, rotate the ignition
key to off and remove the key.
Changing to Machine Operation
• Make sure the grass deflector is in the down
position.
Operating with the Overheat
Sensor
This machine has a sensor that will turn off the mower
deck when the engine overheats. When the engine
overheats, the audible alarm and light alarm will turn on
along with the mower deck turning off.
If the mower deck turns off automatically because
of overheating, the operator will be able to drive the
machine to a safe area and to a truck or trailer.
Figure 31
Using the Side Discharge
If the machine overheats, ensure the area around
the engine and radiator is clear of any debris. The
engine will need to be turned off and allowed to cool
down before the mower deck can be engaged. If the
engine continues to overheat, take your machine to an
Authorized Service Dealer.
The mower has a hinged grass deflector that disperses
clippings to the side and down toward the turf.
Transporting Machines
1. Side console controls
2. By-pass valve
3. Hydraulic pumps
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.
Please carefully read all 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.
28
• Securely fasten the machine to the trailer or truck
with straps, chains, cable, or ropes.
WARNING
Loading a unit onto a trailer or truck increases the
possibility of backward tip-over and could cause
serious injury or death.
• Secure a trailer to the towing vehicle with safety
chains.
• Use extreme caution when operating a unit on
a ramp.
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.
• Use only a single, full width ramp; Do Not use
individual ramps for each side of the unit.
• If individual ramps must be used, use enough
ramps to create an unbroken ramp surface
wider than the unit.
Do not drive machine on a public street or
roadway.
• Do not exceed a 15 degree angle between ramp
and ground or between ramp and trailer or
truck.
Loading Machines
Use extreme caution when loading units on trailers or
trucks. One full width ramp that is wide enough to
extend beyond the rear tires is recommended instead of
individual ramps for each side of the unit (Figure 32).
The lower rear section of the tractor frame extends
back between the rear wheels and serves as a stop for
tipping backward. Having a full width ramp provides
a surface for the frame members to contact if the
unit starts to tip backward. If it is not possible to use
one full width ramp, use enough individual ramps to
simulate a full width continuous ramp.
• Avoid sudden acceleration while driving unit up
a ramp to avoid tipping backward.
• Avoid sudden deceleration while backing unit
down a ramp to avoid tipping backward.
The ramp should be long enough so that the angles
do not exceed 15 degrees (Figure 32). A steeper angle
may cause mower components to get caught as the unit
moves from ramp to trailer or truck. Steeper angles
may also cause the unit to tip backward. If loading on
or near a slope, position the trailer or truck so it is on
the down side of the slope and the ramp extends up the
slope. This will minimize the ramp angle. The trailer or
truck should be as level as possible.
Important: Do Not attempt to turn the unit while
on the ramp; you may lose control and drive off
the side.
Figure 32
1. Trailer
Avoid sudden acceleration when driving up a ramp and
sudden deceleration when backing down a ramp. Both
maneuvers can cause the unit to tip backward.
2. Full width ramp
3. Not greater than
15 degrees
4. Full width ramp—side view
Using the Z Stand®
The Z Stand® raises the front end of the machine to
allow you to clean the mower and remove the blades.
29
WARNING
The machine could fall onto someone and cause
serious injury or death.
• Use extreme caution when operating the
machine on the Z Stand®.
• Use only for cleaning the mower and removing
the blades.
Figure 34
• Do not keep the machine on the Z Stand for
extended periods of time.
1. Z Stand (Positioned in
slot)
2. Crack in side walk or turf
• Always turn the engine off, set the parking
brake, and remove the key before performing
any maintenance to the mower.
3. Latch resting on pivot tab
6. Set the foot of stand on the ground and rest the
latch on the pivot tab (Figure 34).
7. Start the engine and put it at half throttle.
Driving up onto the Z Stand
Note: For best results, place the foot of stand into
seams in sidewalks or into the turf (Figure 34).
8. Drive onto the stand. Stop when the latch drops
over the tab into the locked position (Figure 34).
Once onto the stand, engage the parking brake and
tun off the engine.
9. Chock or block the drive wheels.
Important: Use the Z Stand on a level surface.
1. Raise the mower to the transport position.
2. Remove the bracket pin (Figure 33).
WARNING
Parking brake may not hold machine parked
on Z Stand and could cause personal injury or
property damage.
Do not park on Z Stand unless wheels are
chocked or blocked.
Figure 33
1. Z Stand
2. Latch
3. Bracket
10. Perform the maintenance.
4. Bracket Pin
5. Bottom of slot
Driving off the Z Stand
1. Remove the chocks or blocks.
2. Raise the latch to the unlocked position (Figure 35).
3. Raise the latch. Swing the stand foot out front and
slide stand toward machine, into the bottom of slot
(Figure 33 and Figure 34).
4. Lengthen the Z Stand by removing the clevis pin
and hairpin cotter pin from the outer tube and
sliding the foot out.
5. Align the holes and install the clevis pin and hairpin
cotter pin.
Figure 35
1. Z Stand
2. Latch
30
3. Locked position
4. Unlocked position
3. Start the engine and place it at half throttle.
Disengage the parking brake.
at a high cutting height; then mow again two days later
at a lower height setting.
4. Slowly drive backwards off of the stand.
Cutting Speed
5. Shorten the Z Stand by removing the clevis pin and
hairpin cotter pin from the outer tube and sliding
the foot in.
To improve cut quality, use a slower ground speed in
certain conditions.
6. Align the holes and install the clevis pin and hairpin
cotter pin.
Avoid Cutting Too Low
7. Return the stand to its rest position (Figure 33).
If the cutting width of the mower is wider than the
mower you previously used, raise the cutting height to
ensure that uneven turf is not cut too short.
Operating Tips
Fast Throttle Setting
Long Grass
For best mowing and maximum air circulation, operate
the engine at the fast throttle 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
by uncut grass. Always try to have one side of the
mower free from uncut grass, which allows air to be
drawn into the mower.
If the grass is ever allowed to grow slightly longer than
normal, or if it contains a high degree of moisture, raise
the cutting height higher than usual and cut the grass at
this setting. Then cut the grass again using the lower,
normal setting.
When Stopping
If the machine’s forward motion must be stopped while
mowing, a clump of grass clippings may drop onto your
lawn. To avoid this, move onto a previously cut area
with the blades engaged.
Cutting a Lawn for the First Time
Cut grass slightly longer than normal to ensure the
cutting height of the mower 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 six inches tall, you may want to cut the lawn twice
to ensure an acceptable quality of cut.
Keep the Underside of the Mower
Clean
Clean clippings and dirt from the underside of the
mower after each use. If grass and dirt build up inside
the mower, cutting quality will eventually become
unsatisfactory.
Cut 1/3 of the Grass Blade
It is best to cut only about 1/3 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.
Blade Maintenance
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 cutter blades
daily for sharpness, and for any wear or damage. File
down any nicks and sharpen the blades as necessary. If
a blade is damaged or worn, replace it immediately with
a genuine TORO replacement blade.
Mowing Direction
Alternate mowing direction to keep the grass standing
straight. This also helps disperse clippings which
enhances decomposition and fertilization.
Mow at Correct Intervals
Normally, mow every four days. But remember,
grass grows at different rates at different times. So
to maintain the same cutting height, which is a good
practice, 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
31
Maintenance
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 8 hours
• Check the engine cooling system level.
• Check the hydraulic fluid level.
After the first 25 hours
• Change the hydraulic filter.
After the first 50 hours
• Change the engine oil.
• Change the engine oil filter.
After the first 100 hours
• Check the wheel hub slotted nut.
• Check the wheel lug nuts.
• Change gear box oil.
Before each use or daily
•
•
•
•
•
•
Check the safety system.
Check the engine oil.
Check the engine cooling system level.
Clean the engine oil cooler.
Check the mower blades.
Clean the mower deck.
Every 25 hours
•
•
•
•
•
•
Grease the mower deck and spindles.
Grease the mower belt idler arm.
Grease the pump belt idler arm.
Grease the PTO drive belt idler arm.
Grease the brake lever.
Check the hydraulic fluid level.
Every 40 hours
• Drain the water separator.
Every 50 hours
•
•
•
•
Check the tire pressure. or monthly, whichever occurs first.
Check the PTO drive belt.
Check the pump drive belt.
Check the alternator belt.
Every 100 hours
•
•
•
•
•
Change the engine oil.
Check the gear box oil level.
Check the engine cooling system hoses.
Inspect the belts for cracks and wear.
Check the hydraulic hoses.
Every 150 hours
• Lubricate the machine with light oil (Refer to Lubrication).
Every 200 hours
• Change the engine oil filter.
• Grease the brake pivot.
Every 250 hours
• Check and/or replace the air filter (more often in dirty or dusty conditions).
• Change the hydraulic filter and hydraulic oil when using Mobil® 1 oil.
Every 500 hours
Yearly
•
•
•
•
•
Check the wheel hub slotted nut.
Check the wheel lug nuts.
Adjust the caster pivot bearing.
Adjust the electric clutch.
Change the hydraulic filter and hydraulic oil when using Toro® HYPR-OIL™ 500
hydraulic oil.
• Grease the front caster pivots (more often in dirty or dusty conditions).
• Change the gear box oil.
• Change the engine coolant.
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
32
CAUTION
If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure
you or other bystanders.
Remove the key from the ignition and disconnect the wire from the spark plug(s) before you do any
maintenance. Set the wire aside so that it does not accidentally contact the spark plug.
Lubrication
Greasing and Lubrication
Lubricate the machine when shown on the Check
Service Reference Aid decal (Figure 36). Grease more
frequently when operating conditions are extremely
dusty or sandy.
Grease Type: General-purpose grease.
How to Grease
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Clean the grease fittings with a rag. Make sure to
scrape any paint off the front of the fitting(s).
4. Connect a grease gun to the fitting. Pump grease
into the fittings until grease begins to ooze out of
the bearings.
5. Wipe up any excess grease.
Figure 36
Where to Add Light Oil or Spray
Lubrication
Greasing the Front Caster Pivots
Service Interval: Every 150 hours
Service Interval: Yearly
Lubricate the machine in the following areas with spray
type lubricant or light oil.
• Seat switch actuator.
• Brake handle pivot.
• Brake rod bushings.
• Motion control bronze bushings.
Lubricate the front caster pivots once a year.
1. Remove the dust cap and adjust the caster pivots.
Keep the dust cap off until greasing is done.
Refer to Adjusting the Caster Pivot Bearing in
Drive System Maintenance (page 43).
2. Remove the hex plug. Thread a grease zerk into the
hole.
3. Pump grease into the zerk until it oozes out around
the top bearing.
4. Remove the grease zerk in the hole. Install the hex
plug and cap.
Greasing the Mower Deck and
Belt Idlers
Service Interval: Every 25 hours—Grease the mower
deck and spindles.
Every 25 hours—Grease the mower
belt idler arm.
Every 25 hours—Grease the pump
belt idler arm.
Where to Add Grease
Lubricate the grease fittings as shown on the Check
Service Reference Aid decal (Figure 36).
33
Every 25 hours—Grease the PTO
drive belt idler arm.
Grease with No. 2 general purpose lithium base or
molybdenum base grease.
Important: Make sure cutting unit spindles are
full of grease weekly.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the belt covers.
Figure 38
4. Grease the three spindle bearings until grease comes
out the lower seals (Figure 37).
5. Grease the idler arm on the mower deck (Figure 37).
6. Grease the fittings on the push arms (Figure 37).
Figure 37
7. Grease the PTO drive belt idler arm (Figure 38).
8. Grease the pump belt idler arm (Figure 38).
34
Engine Maintenance
Servicing the Air Cleaner
Note: Check the filters more frequently if operating
conditions are extremely dusty or sandy.
Removing the Air Filter
Service Interval: Every 250 hours
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Release the latches on the air cleaner and pull the air
cleaner cover off of the air cleaner body (Figure 39).
4. Clean the inside of the air cleaner cover with
compressed air.
Figure 39
5. Gently slide the filter out of the air cleaner body
(Figure 39). Avoid knocking the filter into the side
of the body.
1. Air filter body
2. Air filter
6. Inspect the filter for damage by looking into the
filter while shining a bright light on the outside of
the filter. Holes in the filter will appear as bright
spots. If the filter is damaged discard it.
3. Air cleaner cover
4. Latches
Installing the Air Filter
1. If installing a new filter, check the filter for shipping
damage. Do not use a damaged filter.
2. Carefully slide the filter into the filter body
(Figure 40). Ensure that it is fully seated by pushing
on the outer rim of the filter while installing it.
Important: Do not press on the soft inside area
of the filter.
3. Install the air cleaner cover and secure the latches
(Figure 40).
35
Checking the Engine Oil Level
Service Interval: Before each use or daily
Note: Check the oil when the engine is cold.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Clean around the oil dipstick (Figure 42) so dirt
cannot fall into the filler hole and damage the engine.
4. Pull the oil dipstick out and wipe the metal end clean
(Figure 42).
5. Slide the oil dipstick fully into the filler tube. Pull the
dipstick out and look at the metal end (Figure 42). If
the oil level is low, slowly pour only enough oil into
the fill hole to raise the level to the full mark.
Important: Do not overfill the crankcase with
oil because this may cause engine damage. Do
not run the engine with oil below the low mark
because the engine may be damaged as a result.
Figure 40
1. Air filter body
2. Air filter
3. Air cleaner cover
4. Latches
Servicing the Engine Oil
Oil Type: High-quality detergent oil classified API
Service CD or higher for diesel engines. Do not use
special additives with recommended oils.
Crankcase Capacity: 3.9 quarts (3.7 liters)
Viscosity: See the table below:
Figure 42
1. Oil dipstick
2. Metal end
Figure 41
36
3. Rear left side of machine
Changing the Engine Oil
This will prevent you from accidentally stripping
the bolts free of the retainers.
Service Interval: After the first 50 hours
1. Tilt the seat forward, loosen the bolts and remove
the front engine panel (Figure 44).
Every 100 hours
1. Start the engine and let it run for five minutes. This
warms the oil so it drains better.
1
2. Park the machine on a level surface.
3. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
4. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
2
5. Place a pan below the oil drain. Remove the drain
plug and let the oil drain completely (Figure 43).
6. Remove the oil filler cap from the top of the engine
(Figure 45). This will help the oil to drain.
1
7. Install the drain plug and tighten it to 25-1/2 ft-lb
(35 N-m).
G012347
Figure 44
1. Bolt
Note: Dispose of the used oil at a recycling center.
2. Front engine panel
2. Remove the oil filler cap and the dipstick (Figure 45).
Figure 45
1. Engine
Figure 43
1. Back of machine
2. Oil fill cap
2. Drain plug
3. To add oil to the engine, locate and use a hose and
funnel for adding oil (Figure 46).
Adding Engine Oil
4. Add oil slowly, checking the level with the
dipstick frequently until the level reaches the
upper hole on the dipstick. For the correct oil
type and viscosity to use in different temperature
conditions, refer to Servicing the Engine Oil in
Engine Maintenance (page 35), ).
Important: The fasteners for the front engine panel
are designed to remain on the machine after cover
removal. Loosen all of the fasteners a few turns so
that the panel is loose but still attached, then go
back and loosen them until the panel comes free.
37
Changing the Engine Oil Filter
Service Interval: After the first 50 hours
Every 200 hours
1. Drain the oil from the engine; refer to Changing the
Engine Oil.
Place a drip pan beneath the oil drip tray to receive
oil from the oil filter and oil passages in the engine.
2. Turn the filter counterclockwise to remove it
(Figure 48 and Figure 49).
Note: Dispose of the oil filter properly. Recycle in
accordance with local codes.
3. Before installing the filter, lightly oil the gasket on
the filter with fresh, clean oil. Screw the filter on by
hand until the gasket contacts the oil filter adapter.
Tighten 1/2 to 3/4 turn more.
Figure 46
1. Engine oil
2. Funnel and hose
4. Add oil; refer to Adding Engine Oil.
Important: Add the oil very slowly and do not
block the opening of the filler hole (Figure 47).
If you add oil too fast or block the hole, the oil
could back up and foul the air intakes, causing
engine damage.
Figure 47
1. Note the clearance left in the filler opening.
5. Replace the dipstick and install the front engine
panel.
Figure 48
6. Start the engine and run it at idle for 5 minutes.
1. Oil filter
7. Shut off the engine.
8. Wait 3 minutes and check the oil level.
9. Add oil, if required, to bring the level to the upper
hole on the dipstick.
10. Replace the dipstick and , filler cap, and the front
engine panel.
11. Check for leaks.
Important: Do not overfill the crankcase with
oil because this may cause engine damage.
38
2. Right side of machine
Fuel System
Maintenance
Servicing the Fuel Filter
Draining the Water Separator
Service Interval: Every 40 hours
Figure 49
1. Oil filter
2. Gasket
1. Position the machine on a level surface.
3. Adapter
2. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Locate the water separator at the back left of the
machine.
5. Place a drain pan below the water separator.
6. Open the drain valve on the water separator
approximately one turn to allow water and other
contaminates to drain (Figure 50).
7. Close the drain valve when only diesel fuel comes
out (Figure 50).
Figure 50
1. Drain valve
2. Water separator
39
3. Back of machine
Changing the Fuel Filter
Servicing the Fuel Tank
Never install a dirty fuel filter if it is removed from the
fuel line.
Do not attempt to drain the fuel tank because fuel line
components require special tools to install them. Ensure
that an Authorized Service Dealer drains the fuel tank
and services any components of the fuel system.
1. Allow the machine to cool down.
2. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Close the fuel shut-off valve(Figure 51).
5. Loosen the two hose clamps and disconnect the fuel
lines from the fuel filter (Figure 51).
6. Install a new filter. Connect the fuel lines to the fuel
filter and install the two hose clamps (Figure 51).
7. Open the fuel shut-off valve.
8. Start the engine and check for leaks.
Figure 51
1. Fuel filter
2. Hose clamp
3. Fuel pump
4. Left side of machine
5. Fuel shut-off valve
40
Electrical System
Maintenance
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
Servicing the Battery
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Unlatch the seat and tilt the seat up.
WARNING
4. First disconnect the negative battery cable from the
negative (-) battery terminal (Figure 52).
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California
to cause cancer and reproductive harm.
Wash hands after handling.
5. Slide the red terminal boot off the positive (red)
battery terminal. Then remove the positive (red)
battery cable (Figure 52).
DANGER
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to shield
your eyes and rubber gloves to protect your hands.
Removing the Battery
WARNING
Figure 52
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. Negative Battery Post
2. Positive Battery Post
3. Red (+) cable
4. Black (-) cable
6. Remove both wing nuts (1/4 inch) securing the
battery clamp (Figure 53).
7. Remove the two bolts holding the hydraulic tank in
place (Figure 53).
8. Slide the hydraulic tank away from the battery.
9. Remove the battery.
WARNING
Incorrect battery cable routing could damage the
machine and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always Disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always Reconnect the positive (red) battery
cable before reconnecting the negative (black)
cable.
41
to prevent battery damage when the temperature is
below 32°F (0°C).
1. Make sure the filler caps are installed in battery.
Charge battery for 10 to 15 minutes at 25 to 30 amps
or 30 minutes at 10 amps.
2. When the battery is fully charged, unplug the charger
from the electrical outlet, then disconnect the
charger leads from the battery posts (Figure 54).
3. Install the battery in the machine and connect the
battery cables, refer to Installing the Battery.
Note: Do not run the machine with the battery
disconnected, electrical damage may occur.
Figure 53
1. Battery
2. Hydraulic tank
3. Bolts
4. Wing nut
5. Right side fuel tank
Installing the Battery
1. Position battery in the tray with the terminal posts
opposite from the hydraulic tank (Figure 53).
2. First, install the positive (red) battery cable to
positive (+) battery terminal.
3. Then install the negative battery cable and ground
wire to the negative (-) battery terminal.
4. Secure the cables with 2 bolts (1/4 x 3/4 inch),
2 washers (1/4 inch), and 2 locknuts (1/4 inch)
(Figure 52).
5. Slide the red terminal boot onto the positive (red)
battery post.
6. Secure battery with J-bolts, hold down clamp and
2 washers (1/4 inch), and 2 wing nuts (1/4 inch)
(Figure 53).
Figure 54
1. Positive Battery Post
2. Negative Battery Post
3. Red (+) Charger Lead
4. Black (-) Charger Lead
Servicing the Fuses
The electrical system is protected by fuses. It requires
no maintenance, however, if a fuse blows check
component/circuit for malfunction or short.
1. Unlatch the engine hood and raise the engine hood
to gain access to fuse holder (Figure 55).
2. To replace the fuses, pull out on the fuse to remove
it.
Charging the Battery
3. Install a new fuse (Figure 55).
WARNING
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
Important: Always keep the battery fully charged
(1.265 specific gravity). This is especially important
42
Drive System
Maintenance
1
4
3
Adjusting the Tracking
The machine has a knob for adjusting the tracking
located under the seat.
2
Important: Adjust the handle neutral and
hydraulic pump neutral before adjusting the
tracking. Refer to Adjusting the Handle Neutral
in Controls System Maintenance (page 52)
and Adjusting the Hydraulic Pump Neutral
in Hydraulic System Maintenance (page 53).
1. Push both control levers forward the same distance.
G012492
2. Check if the machine pulls to one side. If it does,
stop the machine and set the parking brake.
Figure 55
1. Ignition-30 amp (F1)
2. Radiator fan-50 amp
(large, heavy duty fuse)
3. Unlatch the seat and tilt the seat forward to access
the tracking knob.
3. Clutch-10 amp (F3)
4. Left side fuel tank
Note: Determine the left and right sides of the
machine from the normal operating position.
4. To make the machine go right, turn the knob towards
the rightside of the machine. Refer to Figure 56.
5. To make the machine go left, turn the knob towards
the leftside of the machine. Refer to Figure 56.
6. Repeat adjustment until the tracking is correct.
43
Checking the Wheel Hub
Slotted Nut
Service Interval: After the first 100 hours—Check the
wheel hub slotted nut.
Every 500 hours—Check the wheel
hub slotted nut.
After the first 100 hours—Check the
wheel lug nuts.
Every 500 hours—Check the wheel
lug nuts.
The slotted nut needs to be torqued to 125 ft-lb
(170 N-m).
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Figure 56
1. Tracking knob
2. Hydraulic tank
3. Hydraulic pumps
3. Remove the cotter pin.
4. Turn this way to track right
5. Turn this way to track left
4. Torque the slotted nut to 125 ft-lb (170 N-m)
(Figure 58).
Checking the Tire Pressure
Service Interval: Every 50 hours or monthly, whichever
occurs first.
Check the pressure at the valve stem (Figure 57).
Maintain the air pressure in the rear tires at 13 psi (90
kPa). Uneven tire pressure can cause uneven cut. Check
the tires when they are cold to get the most accurate
pressure reading.
Figure 58
1. Slotted Nut
2. Two threads or less
showing
Note: The front tires are semi-pneumatic tires and do
not require air pressure maintenance.
3. Hole in threaded shaft
4. Washer (if needed)
5. Check the distance from bottom of slot in nut to
inside edge of hole. Two threads or less should be
showing (Figure 58).
6. If more than two threads are showing remove nut
and install washer between hub and nut.
7. Torque the slotted nut to 125 ft-lb. (170 N-m)
(Figure 58).
8. Tighten the nut until the next set of slots line up with
the hole in the shaft (Figure 58).
Figure 57
9. Replace the cotter pin.
44
Adjusting the Caster Pivot
Bearing
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Remove the side or rear plug on the gear box.
(Figure 60).
5. The oil should be up to the opening of the gear box.
6. Add oil if needed to bring it to the correct level.
Service Interval: Every 500 hours
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the dust cap from caster and tighten lock
nut (Figure 59).
4. Tighten the locknut until the spring washers are flat
and then back off a 1/4 turn to properly set the
pre-load on the bearings (Figure 59).
Important: Make sure spring washers are
installed correctly as shown in Figure 59.
5. Install the dust cap (Figure 59).
Figure 60
1. Gear box
2. Side plug
3. Rear plug
4. Pulley
Changing the Gear Box Oil
Service Interval: After the first 100 hours
Yearly
Figure 59
1. Spring Washers
2. Lock Nut
3. Dust Cap
Contact an Authorized Service Dealer to change the
gear box oil.
Adjusting the Electric Clutch
Servicing the Gear Box
Service Interval: Every 500 hours
Checking the Gear Box Oil Level
The clutch is adjustable to ensure proper engagement
and proper braking.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Service Interval: Every 100 hours
Use SAE 75W–90 Synthetic Gear Lube.
1. Park the machine on a level surface.
2. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
45
3. Tilt the seat forward, loosen the bolts and remove
the front engine panel.
8. Insert a 0.015–0.021 inch (0.381–0.533 mm) feeler
gauge through one inspection slot in the side of the
assembly. Make sure it is between the armature and
the rotor friction surfaces (Figure 63).
4. Pull up on the spring loaded idler pulley for the PTO
drive belt and remove the belt from the clutch pulley
(Figure 61).
9. Tighten the lock nuts until there is slight binding on
the feeler gauge but it can be moved easily within the
air gap (Figure 63).
10. Repeat this for the remaining slots.
11. Check each slot again and make slight adjustments
until the feeler gauge between the rotor and armature
with very slight contact between them.
Figure 63
Figure 61
1. Spring loaded idler pulley
2. Clutch
1. Slot
2. Adjusting nut
3. PTO drive belt
4. Gear box
3. Feeler gauge
12. Install the clutch to the engine shaft with the key.
5. Unplug the electric connection for the clutch
(Figure 62).
13. Apply blue Loctite® (or equivalent) to the center
bolt.
6. Remove the two bolts holding the rubber clutch
strap to the mower frame (Figure 62).
14. While holding the crank shaft at the back of the
machine, install the center bolt and torque it to 50
ft-lbs (68 N-m) (Figure 62).
7. Remove the center bolt holding the clutch to
the engine shaft and remove the clutch and key
(Figure 62).
15. Install the rubber clutch strap to the mower frame
with the two previously removed bolts and nuts
(Figure 62).
16. Pull up on the spring loaded idler for the PTO drive
belt and install it onto the clutch pulley (Figure 61).
17. Plug in the electric connection for the clutch
(Figure 62).
18. Install the front engine panel.
19. Lower down the seat.
Figure 62
1. Clutch
2. Two bolts and nuts for
clutch strap
3. Rubber clutch strap
4. Clutch center bolt
5. Electrical connection
46
Cooling System
Maintenance
3. With the engine cool, check the overflow bottle level.
The fluid needs to be up to the bump on the outside
of the overflow bottle (Figure 64).
Servicing the Cooling System
4. If the coolant level is low, add a 50/50 mix of
extended life antifreeze/Dex-Cool® and water to
the overflow bottle (Figure 64).
DANGER
5. Add the 50/50 coolant mix to the overflow
bottle and fill it to the indicator line on the bottle
(Figure 64).
Discharge of hot pressurized coolant or touching
hot radiator and surrounding parts can cause severe
burns.
• Do not remove the radiator cap when the engine
is hot. Always allow the engine to cool at least
15 minutes or until the radiator cap is cool
enough to touch without burning your hand
before removing the radiator cap.
• Do not touch radiator and surrounding parts
that are hot.
WARNING
Rotating shaft and fan can cause personal injury.
• Do not operate the machine without the covers
in place.
• Keep fingers, hands and clothing clear of
rotating fan and drive shaft.
• Shut off the engine and remove the ignition key
before performing maintenance.
Figure 64
1. Antifreeze overflow bottle
2. Indicator line on side of
overflow bottle
CAUTION
Swallowing engine coolant can cause poisoning.
• Do not swallow engine coolant.
• Keep out of reach from children and pets.
Cleaning the Engine Oil Cooler and
Radiator Screen
Service Interval: Before each use or daily
Checking the Engine Coolant Level
Before each use, check and clean the radiator screen
and oil cooler. Remove any build-up of grass, dirt or
other debris from the oil cooler and radiator screen with
compressed air (Figure 65).
Service Interval: Before each use or daily
After the first 8 hours
Every 100 hours
Fluid Type: 50/50 mix of extended life
antifreeze/Dex-Cool® and water
Cooling System Capacity: 156 ounces (4.6 l)
Note: Do not open the radiator cap. Doing this may
induce air into the cooling system.
1. Position the machine on a level surface, stop the
engine, and set the parking brake.
2. Unlatch the seat and tilt the seat up.
47
Brake Maintenance
Adjusting the Parking Brake
Service Interval: Every 25 hours
Every 200 hours
1. Engage the parking brake, lever up.
2. Measure the length of the spring. Measurement
should be 2-1/2 inch (64 mm) between the washers
(Figure 66).
3. If adjustment is necessary, release the parking brake,
loosen the jam nut below the spring and adjust the
nut directly below the spring (Figure 66). Turn the
nut until the correct measurement is obtained. Turn
the nut clockwise to shorten spring length and turn
counter-clockwise to lengthen the spring.
Figure 65
1. Hydraulic oil cooler
2. Left rear tire
4. Tighten the two nuts together.
3. Radiator screen
5. Engage the parking brake, lever up. Check the
measurement of the spring again.
6. If adjustment is necessary, repeat the procedures
above.
Changing the Engine Coolant
7. Repeat on the opposite side of machine.
Service Interval: Yearly
Have an Authorized Service Dealer change the engine
coolant every year.
Figure 66
1. Brake lever in engaged
3. Adjusting nut and jam nut
position
2. Spring 2–1/2 inch (64 mm)
48
Belt Maintenance
4
3
Inspecting the Belts
Service Interval: Every 100 hours
1
2
Check belts for cracks, frayed edges, burn marks, or any
other damage. Replace damaged belts.
Replacing the Mower Belt
Squealing when the belt is rotating, blades slipping when
cutting grass, frayed belt edges, burn marks and cracks
are signs of a worn mower belt. Replace the mower belt
if any of these conditions are evident.
g012495
Figure 67
1. Belt cover
2. Latch
Important: The fasteners on the mower deck
covers of this machine are designed to remain on
the cover after removal. Loosen all of the fasteners
on each cover a few turns so that the cover is loose
but still attached, then go back and loosen them
until the cover comes free. This will prevent you
from accidentally stripping the bolts free of the
retainers.
3. Bolt
4. Insert tab into the tab
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Remove the belt covers and the bolts attached to
them (Figure 67).
4. Remove the spring and belt guide from the idler arm.
Figure 68
5. Remove the existing belt if needed.
1. Mower belt
2. Mower spindle pulley
3. Mower idler pulley
6. Install the new belt around the mower pulleys and
the gearbox pulley under the engine (Figure 68).
7. Install the belt guide on the spring loaded idler at a
45 degree angle as shown in Figure 68. Torque the
bolt to 27 to 33 ft-lb (37 to 45 N-m).
4. Belt guide
5. Gearbox pulley
6. Spring
Replacing the PTO Drive Belt
8. Install the idler spring to the two posts (Figure 68).
Service Interval: Every 50 hours—Check the PTO
drive belt.
9. Install the belt covers by sliding the cover into
the tab, tighten the bolts, and close the latches
(Figure 67).
Important: The fasteners for the front engine panel
are designed to remain on the machine after cover
removal. Loosen all of the fasteners a few turns so
that the panel is loose but still attached, then go
back and loosen them until the panel comes free.
This will prevent you from accidentally stripping
the bolts free of the retainers.
49
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Tilt the seat forward, loosen the bolts and remove
the front engine panel (Figure 69).
1
Figure 70
1. Gear box
2. Spring
3. Spring loaded idler pulley
4. Clutch
5. Rubber clutch stop
6. PTO Drive belt
2
Replacing the Pump Drive Belt
1
Service Interval: Every 50 hours—Check the pump
drive belt.
G012347
Figure 69
1. Bolts
2. Front engine panel
Note: Remove the PTO drive belt first if the pump
drive belt needs to be replaced.
4. Remove the spring from the idler arm (Figure 70).
5. Remove the clutch stop bracket.
1. Tilt the seat forward, loosen the bolts and remove
the front engine panel.
6. Remove the old PTO drive belt.
2. Remove the PTO drive belt.
7. Install the PTO drive belt around the clutch pulley
and the gearbox pulley (Figure 70).
3. Remove the spring from the idler arm (Figure 71).
8. Install the rubber clutch stop.
4. Install the new belt around the engine and hydro
pump pulley (Figure 71).
9. Install the spring to the idler arm (Figure 70).
5. Install the PTO drive belt.
10. Install the front engine panel.
6. Install the spring to the idler arm (Figure 71).
7. Install the front engine panel.
50
Figure 71
1. Clutch
2. Pump drive belt
3. Spring
4. Spring loaded idler pulley
Replacing and Tensioning the
Alternator Belt
Figure 72
1. Alternator
4. Top bolt
2. Alternator belt
5. Bottom bolt
3. Deflection, 1/4 to
11/32 inch (7 to 9 mm) with
22.1 lbs of force (10 kgf)
Replacing the Alternator Belt
Service Interval: Every 50 hours—Check the alternator
belt.
If the alternator belt needs to be replace, take your
machine to an Authorized Service Dealer.
Tensioning the Alternator Belt
1. Place a handle between the alternator and cylinder
block.
2. Adjust the alternator to the outside until there is
1/4 to 11/32 inch (7 to 9 mm) deflection in the belt
between the engine and the alternator pulleys with
22.1 lbs of force (10 kgf) (Figure 72).
3. Tighten the alternator bolts.
4. Check the deflection in the belt again and adjust the
belt if needed.
5. If the deflection is correct, tighten the bottom and
upper bolt (Figure 72).
51
Controls System
Maintenance
9. Apply slight rearward pressure on the motion
control lever, turn the head of the adjustment bolt
in the appropriate direction until the control lever is
centered in the neutral lock position (Figure 74).
Adjusting the Control Handle
Neutral Position
Note: Keeping rearward pressure on the lever will
keep the pin at the end of the slot and allow the
adjustment bolt to move the lever to the appropriate
position.
If motion control levers do not align, or move easily into
the console notch, adjustment is required. Adjust each
lever, spring and rod separately.
10. Tighten the nut and jam nut (Figure 74).
11. Repeat for the opposite side of the machine.
Note: Motion control levers must be installed correctly.
See Installing the Motion Control Levers in the set up
instructions.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
3. Unlatch the seat and tilt the seat forward.
4. Begin with either the left or right motion control
lever.
5. Move the lever to the neutral position but not locked
(Figure 73).
6. Pull the lever back until the clevis pin (on arm
below pivot shaft) contacts the end of the slot (just
beginning to put pressure on the spring) (Figure 73).
Figure 74
1.
2.
3.
4.
7. Check where the control lever is relative to notch in
console (Figure 73). It should be centered allowing
lever to pivot outward to the neutral lock position.
Figure 73
1. Neutral locked position
2. Control lever
3. Neutral potion
8. If adjustment is needed, loosen the nut and jam nut
against the yoke (Figure 74).
52
Height-of-cut lever
Nut against yoke
Jam Nut
Clevis pin in slot
5. Adjustment bolt
6. Yoke
7. Spring
Hydraulic System
Maintenance
Servicing the Hydraulic
System
Hydraulic Oil Type: Toro® HYPR-OIL™ 500
hydraulic oil or Mobil® 1 15W-50
Figure 75
Hydraulic System Oil Capacity: 132 ounces (3.9l)
1. Cap
2. Baffle
Important: Use oil specified. Other fluids could
cause system damage.
3. Cold fluid level-full
4. Hot fluid level-full
WARNING
Checking the Hydraulic Fluid Level
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin
it must be surgically removed within a few
hours by a doctor familiar with this type of
injury. Gangrene may result if this is not
done.
• Keep body and hands away from pin hole
leaks or nozzles that eject high pressure
hydraulic fluid.
• Use cardboard or paper to find hydraulic
leaks.
• Safely relieve all pressure in the hydraulic
system before performing any work on the
hydraulic system.
• Make sure all hydraulic fluid hoses and
lines are in good condition and all hydraulic
connections and fittings are tight before
applying pressure to hydraulic system.
Service Interval: After the first 8 hours
Every 25 hours
Important: Use oil specified or equivalent. Other
fluids could cause system damage.
Note: There are two ways of checking the hydraulic oil.
One is when the oil is warm and one is when the oil is
cold. The baffle inside the tank has two levels depending
if the oil is warm or cold.
1. Position the machine on a level surface and set the
parking brake.
2. Clean the area around filler neck of hydraulic tank
(Figure 75).
3. Remove the cap from the filler neck. Look inside to
check if there is fluid in the reservoir (Figure 75).
4. If there is no fluid, add fluid to the reservoir until it
reaches the cold level of the baffle.
5. Run the machine at low idle for 15 minutes to allow
any air to purge out of the system and warm the fluid.
Refer to Starting and Stopping the Engine (page 20).
Replacing the Hydraulic Filter and
Hydraulic Oil
Service Interval: After the first 25 hours
Every 250 hours—Change the
hydraulic filter and hydraulic oil when
using Mobil® 1 oil.
Every 500 hours—Change the
hydraulic filter and hydraulic oil
when using Toro® HYPR-OIL™ 500
hydraulic oil.
6. Recheck the fluid level while the fluid is warm. The
fluid should be between cold and hot.
7. If required, add fluid to the hydraulic tank.
Note: The fluid level should be to the top of the hot
level of the baffle, when the fluid is hot (Figure 75).
8. Install cap on filler neck.
Use summer filter above 32°F (0°C)
Use winter filter below 32°F (0°C)
Note: At the yearly interval, change the hydraulic oil
when the oil filter is changed.
53
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Important: Do not substitute automotive oil
filter or severe hydraulic system damage may
result.
3. Place drain pan under filter, remove the old filter
and wipe the filter adapter gasket surface clean
(Figure 76).
Figure 77
1. Hydraulic filter
2. Gasket
3. Adapter
Bleeding the Hydraulic System
The traction system is self bleeding, however, it may be
necessary to bleed the system if fluid is changed or after
work is performed on the system.
1. Raise rear of the machine so wheels are off the
ground and support with jack stands.
Figure 76
1. Hydraulic filter
2. Start the engine and run at low idle speed. Engage
the lever and traction on one side and spin the wheel
by hand.
4. Apply a thin coat hydro fluid to the rubber gasket on
the replacement filter (Figure 77).
5. If changing the oil, allow the hydraulic oil to drain
from the tank when the oil filter is removed.
3. When the wheel begins to spin on its own, keep it
engaged until wheel drives smoothly. (minimum
2 minutes)
6. Install the replacement hydraulic filter onto the filter
adapter. Do not tighten.
4. Check hydraulic fluid level and add as required to
maintain proper level.
7. Fill the hydraulic tank with hydraulic fluid until the
fluid overflows the filter and then turn the oil filter
clockwise until the rubber gasket contacts the filter
adapter, then tighten the filter an additional 1/2 turn
(Figure 77).
5. Repeat this procedure on the opposite wheel.
8. Clean up any spilled fluid.
Check the hydraulic hoses for leaks, loose fittings,
kinked lines, loose mounting supports, wear, weather
and chemical deterioration. Make necessary repairs
before operating.
Checking the Hydraulic Hoses
Service Interval: Every 100 hours
9. Add fluid to the cold level of the baffle in the
hydraulic tank.
10. Start the engine and let it run for about two minutes
to purge air from the system. Stop the engine and
check for leaks. If one or both wheels will not drive,
refer to Bleeding Hydraulic System.
Note: Keep areas around the hydraulic system clean
from grass and debris build up.
11. Recheck the fluid level while the fluid is warm. The
fluid should be between cold and hot.
12. If required, add fluid to the hydraulic tank. Do not
overfill.
54
Setting the Right-hand Hydraulic Pump
Neutral Position
WARNING
Hydraulic fluid escaping under pressure can
penetrate skin and cause injury.
• If hydraulic fluid is injected into the skin it
must be surgically removed within a few hours
by a doctor familiar with this type of injury.
Gangrene may result if this is not done.
• Keep body and hands away from pin hole leaks
or nozzles that eject high pressure hydraulic
fluid.
• Use cardboard or paper to find hydraulic leaks.
• Safely relieve all pressure in the hydraulic system
before performing any work on the hydraulic
system.
• Make sure all hydraulic fluid hoses and lines are
in good condition and all hydraulic connections
and fittings are tight before applying pressure to
hydraulic system.
1. Start the engine, open the throttle 1/2 way and
release parking brake. Refer to Starting and Stopping
the Engine in Operation.
Note: The motion control lever must be in neutral
while making any adjustments.
2. Adjust the pump rod length by rotating the knob, in
the appropriate direction, until the wheel is still or
slightly creeping in reverse (Figure 78).
3. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning
or slightly creep in reverse.
4. Open the throttle to fast. Make sure wheel remains
stopped or slightly creeps in reverse, adjust if
necessary.
Setting the Hydraulic Pump
Neutral Position
Note: Adjust the handle neutral first. That needs to be
correct before the following adjustment can be made.
This adjustment must be made with drive wheels turning.
DANGER
Mechanical or hydraulic jacks may fail to support
machine and cause a serious injury.
• Use jack stand when supporting machine.
• Do not use hydraulic jacks.
WARNING
Engine must be running so motion control
adjustment can be performed. Contact with moving
parts or hot surfaces may cause personal injury.
Figure 78
Keep hands, feet, face, clothing and other body
parts away from rotating parts, muffler and other
hot surfaces.
1. Tracking knob
2. Hydraulic tank
3. Hydraulic pumps
1. Raise the frame and block up the machine so drive
wheels can rotate freely.
2. Disconnect the electrical connector from the seat
safety switch. Temporarily install a jumper wire
across terminals in the wiring harness connector.
3. Unlatch the seat and slide seat forward.
4. Disconnect the seat rod and tilt the seat fully forward.
4. Turn this way to track right
5. Turn this way to track left
Setting the Left-hand Hydraulic Pump
Neutral Position
1. Loosen the locknuts at the ball joints on the pump
control rod (Figure 79).
55
2. Start the engine, open throttle 1/2 way and release
parking brake. Refer to Starting and Stopping the
Engine in Operation.
WARNING
Electrical system will not perform proper safety
shut off with jumper wire installed.
Note: The motion control lever must be in neutral
while making any adjustments.
• Remove jumper wire from wire harness
connector and plug connector into seat
switch when adjustment is completed.
Note: The front nut on the pump rod has left-hand
threads.
• Never operate this unit with jumper installed
and seat switch bypassed.
3. Adjust the pump rod length by rotating double nuts
on rod, in the appropriate direction, until wheel is
still or slightly creeps in reverse (Figure 79).
7. After both pump neutrals are set, shut off the
machine.
4. Move the motion control lever forward and reverse,
then back to neutral. The wheel must stop turning
or slightly creep in reverse.
8. Remove the jumper wire from the wire harness
connector and plug the connector into the seat
switch.
5. Open the throttle to fast. Make sure the wheel
remains stopped or slightly creeps in reverse, adjust
if necessary.
9. Install the seat rod and lower the seat into position.
10. Remove the jack stands.
6. Tighten the locknuts at the ball joints (Figure 79).
Figure 79
1. Double nuts
2. Pump rod
3. Adjustment bolt
4. Locknut
5. Ball joint
6. Pumps
56
Mower Deck
Maintenance
2. Measure the right blade at the B location, from a
level surface to the cutting edge of the blade tip
(Figure 80).
3. Record this measurement. This measurement needs
to be 3-1/8 to 3-1/4 inches.
4. Position the left blade side-to-side (Figure 80).
5. Measure the left blade at the C location (Figure 80),
from a level surface to the cutting edge of the blade
tip.
6. Record this measurement. This measurement needs
to be 3-1/8 to 3-1/4 inches (80 to 83 mm).
7. If the measurements at positions B or C are not
correct, loosen the bolt attaching the rear chain to
the rear support arm (Figure 81).
Leveling the Mower at Three
Positions
Setting Up the Machine
1. Position mower on a flat surface.
2. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
3. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
4. Check tire pressure of all four tires. If needed, adjust
to 13 psi (90 kPa)
5. Lower the mower to the 3 inch (76 mm) height-of-cut
position.
6. Inspect the four chains. The chains need to have
tension.
• If one rear chain is loose, lower (loosen) the front
support arm on the same side. Refer to Adjusting
the Front-to-Rear Mower Pitch.
• If one front chain is loose, raise (tighten) the front
support arm for that chain. Refer to Adjusting the
Front-to-Rear Mower Pitch.
Figure 81
1.
2.
3.
4.
Leveling the Mower Side-to-Side
Rear chain
Rear support arm
Bolt
Jam Nut
5. Adjustment bolt
6. Front swivel
7. Front support arm
1. Position the right blade side-to-side (Figure 80).
8. Loosen the jam nut under the rear support arm and
adjust the adjustment bolt to get a measurement of
3-1/8 to 3-1/4 inches (80 to 83 mm)(Figure 81).
Note: It is recommended that both sides of the
mower are adjusted the same distance.
9. Tighten the jam nut under the rear support arm
and tighten the bolt securing the chain to the rear
support arm.
10. Adjust the opposite side if needed.
Adjusting the Front-to-Rear Mower
Pitch
1. Position the right blade front-to-rear (Figure 82).
2. Measure the right blade at the A location, from
a level surface to the cutting edge of the blade
tip(Figure 82).
Figure 80
1. Measure here from blade
to hard surface
2. Measure at B and C
57
the spring; counter-clockwise will lengthen the
spring.
4. Lock the nut into position by tightening the spring
jam nut (Figure 83).
Figure 82
1. Measure here from blade
to hard surface
2. Measure at A and B
3. Record this measurement.
4. Measure the right blade at the B location, from a
level surface to the cutting edge of the blade tip
(Figure 82).
Figure 83
1. 11–1/8 inch (28.2 cm)
between the large washers
for 52 inch mower decks
2. Front nut
3. Spring jam nut
4. Front swivel
5. Record this measurement.
6. The mower blade should be a 1/4 to 3/8 inch
(6 to 10 mm) lower at position A than at position
B (Figure 82). If it is not correct, proceed to the
following steps.
6. Lift nut
7. Front support arm
8. Large washer
9. 10-1/2 inch (26.7 cm)
between the large washers
for 60 inch mower decks
5. Swivel jam nut
Note: Both of the front swivels need to be adjusted
the same amount to maintain equal chain tension.
Servicing the Cutting Blades
7. Loosen the front swivel jam nuts, at the front of
the right and left swivels, approximately a 1/2 inch
(13 mm) (Figure 81).
Maintain sharp blades throughout the cutting season
because sharp blades cut cleanly without tearing or
shredding the grass blades. Tearing and shredding turns
grass brown at the edges, which slows growth and
increases the chance of disease.
8. Adjust the lift nuts on both the left and the right
side of the machine to achieve 1/4 to 3/8 inch
(6 to 10 mm) lower in front at A than in the rear at
B (Figure 81).
Check the cutter blades daily for sharpness, and for any
wear or damage. File down any nicks and sharpen the
blades as necessary. If a blade is damaged or worn,
replace it immediately with a genuine Toro replacement
blade. For convenient sharpening and replacement, you
may want to keep extra blades on hand.
9. Tighten both swivel jam nuts against the front swivel
to lock the height.
10. Check to make sure there is equal tension on the
chains and adjust again if needed.
Adjusting the Compression Spring
DANGER
1. Raise the mower lift lever to the transport position.
A worn or damaged blade can break, and a piece
of the blade could be thrown into the operator’s
or bystander’s area, resulting in serious personal
injury or death.
2. Check the distance between the two large washers,
it needs to be 11-1/8 inches (28.2 cm) for 52 inch
mower decks and 10-1/2 inches (26.7 cm) for 60
inch mower decks (Figure 83).
• Inspect the blade periodically for wear or
damage.
3. Adjust this distance, by loosening the spring jam
nut and turning the nut in front of each spring
(Figure 83). Turning the nut clockwise will shorten
• Replace a worn or damaged blade.
58
Before Inspecting or Servicing the
Blades
Park the machine on a level surface, disengage the blade
control (PTO), and set the parking brake. Turn the
ignition key to Off. Remove the key.
Inspecting the Blades
Service Interval: Before each use or daily
1. Inspect the cutting edges (Figure 84). If the edges
are not sharp or have nicks, remove and sharpen the
blades. Refer to Sharpening the Blades.
2. Inspect the blades, especially the curved area
(Figure 84). If you notice any damage, wear, or a slot
forming in this area (Figure 84), immediately install a
new blade.
Figure 85
1. Measure here from blade
to hard surface
2. Position A
4. Rotate the opposite ends of the blades forward.
5. Measure from a level surface to the cutting edge of
the blades at the same position as in step 3 above.
The difference between the dimensions obtained in
steps 3 and 4 must not exceed 1/8 inch (3 mm). If
this dimension exceeds 1/8 inch (3 mm), the blade
is bent and must be replaced; refer to Removing the
Blades and Installing the Blades.
Figure 84
1. Cutting Edge
2. Curved Area
3. Wear/slot Forming
4. Crack
WARNING
A blade that is bent or damaged could break
apart and could seriously injure or kill you or
bystanders.
Checking for Bent Blades
• Always replace bent or damaged blade with
a new blade.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
• Never file or create sharp notches in the
edges or surfaces of blade.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Removing the Blades
3. Rotate the blades until the ends face forward and
backward (Figure 85). Measure from a level surface
to the cutting edge, position A, of the blades
(Figure 85). Note this dimension.
Blades must be replaced if a solid object is hit, if the
blade is out of balance or is bent. To ensure optimum
performance and continued safety conformance of
the machine, use genuine Toro replacement blades.
Replacement blades made by other manufacturers may
result in non-conformance with safety standards.
WARNING
Contact with a sharp blade can cause serious injury.
Wear gloves or wrap sharp edges of the blade with
a rag.
59
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 88).
Sharpening the Blades
WARNING
When sharpening blade, pieces of blade could be
thrown and cause serious injury.
Wear proper eye protection when sharpening blade.
1. Use a file to sharpen the cutting edge at both ends
of the blade (Figure 86). Maintain the original angle.
The blade retains its balance if the same amount of
material is removed from both cutting edges.
Figure 88
1. Sail Area of Blade
2. Blade
3. Curved washer
4. Blade Bolt
Replacing the Grass Deflector
WARNING
Figure 86
An uncovered discharge opening could allow the
lawn mower to throw objects in the operator’s or
bystander’s direction and result in serious injury.
Also, contact with the blade could occur.
1. Sharpen at original angle
2. Check the balance of the blade by putting it on a
blade balancer (Figure 87). If the blade stays in a
horizontal position, the blade is balanced and can be
used. If the blade is not balanced, file some metal off
the end of the sail area only (Figure 88). Repeat this
procedure until the blade is balanced.
• Never operate the lawn mower unless you install
a cover plate, a mulch plate, or a grass chute and
catcher.
• Make sure the grass deflector is in the down
position.
1. Remove the locknut, bolt, spring and spacer holding
the deflector to the pivot brackets (Figure 89).
Remove the damaged or worn grass deflector.
Figure 87
1. Blade
2. Place the spacer and spring onto grass deflector.
Place the L end of spring behind deck edge.
2. Balancer
Note: Make sure the L end of the spring is installed
behind the deck edge before installing the bolt as
shown in Figure 89.
Installing the Blades
1. Install the blade onto the spindle shaft (Figure 88).
3. Install the bolt and nut. Place the J hook end of the
spring around the grass deflector (Figure 89).
Important: The curved part of the blade must
be pointing upward toward the inside of the
mower to ensure proper cutting.
Important: The grass deflector must be able to
lower down into position. Lift the deflector up
to test that it lowers into the full down position.
2. Install the curved washer and blade bolt. The curved
washer cone must be installed toward the bolt head
(Figure 88). Torque the blade bolt to 85-110 ft-lb
(115-150 N-m).
60
Cleaning
Cleaning Under the Mower
Service Interval: Before each use or daily
Remove the grass buildup under the mower daily.
1. Disengage the PTO, move the motion control levers
to the neutral locked position and set the parking
brake.
2. Stop the engine, remove the key, and wait for all
moving parts to stop before leaving the operating
position.
Figure 89
1. Bolt
2. Spacer
3. Locknut
4. Spring
5. Spring installed
6. Grass Deflector
7. L end of spring, place
behind deck edge before
installing bolt
8. J hook end of spring
3. Raise the mower to the transport position.
Waste Disposal
Engine oil, batteries, hydraulic oil, and engine coolant
are pollutants to the environment. Dispose of these
according to your state and local regulations.
61
Storage
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh fuel and used
at all times.
Cleaning and Storage
B. Run the engine to distribute conditioned fuel
through the fuel system (5 minutes).
1. Disengage the power take off (PTO), set the parking
brake, and turn the ignition key to Off. Remove the
key.
C. Stop the engine, allow it to cool, and drain the
fuel tank; refer to Servicing the Fuel Tank in
Fuel System Maintenance (page 39).
2. 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.
D. Restart the engine and run it until it stops.
E. Dispose of fuel properly. Recycle as per local
codes.
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.
Important: Do not store
stabilizer/conditioned fuel over 90 days.
13. Check and tighten all bolts, nuts, and screws. Repair
or replace any part that is damaged.
3. Check the brake; refer to Servicing the Brake in
Brake Maintenance (page 48).
14. Paint all scratched or bare metal surfaces. Paint is
available from your Authorized Service Dealer.
4. Service the air cleaner; refer to Servicing the Air
Cleaner in Engine Maintenance (page 35).
15. Store the machine in a clean, dry garage or storage
area. Remove the key from the ignition switch and
keep it out of reach of children or other unauthorized
users. Cover the machine to protect it and keep it
clean.
5. Grease the machine; refer to Greasing and
Lubrication in Lubrication (page 33).
6. Change the crankcase oil; refer to Servicing the
Engine Oil in Engine Maintenance (page 35).
7. Check the tire pressure; refer to Checking the Tire
Pressure in Drive System Maintenance (page 43).
8. Change the hydraulic filter; refer to
Servicing the Hydraulic System in
Hydraulic System Maintenance (page 53).
9. Charge the battery; refer to Servicing the Battery in
Electrical System Maintenance (page 41).
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 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 in
Mower Deck Maintenance (page 57).
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 an
alcohol based stabilizer (ethanol or methanol).
62
Troubleshooting
Problem
The starter does not crank.
The engine will not start, starts hard, or
fails to keep running.
Possible Cause
1. The blade control (PTO) is engaged.
1. Move the blade control (PTO) to the
disengaged position.
2.
3.
4.
5.
The parking brake is not on.
The operator is not seated.
The battery is dead.
The electrical connections are corroded
or loose.
6. The fuse is blown.
7. The relay or switch is defective.
2.
3.
4.
5.
1. The fuel tank is empty.
1. Fill the fuel tank with fuel.
2. The air cleaner is dirty.
2. Clean or replace the air cleaner
element.
3. Replace the fuel filter.
4. Contact an Authorized Service Dealer.
3. Dirt is in the fuel filter.
4. Dirt, water, or stale fuel is in the fuel
system.
The engine loses power.
The engine overheats.
The machine does not drive.
Abnormal vibration.
Corrective Action
Set the parking brake.
Sit on the seat.
Charge the battery.
Check the electrical connections for
good contact.
6. Replace the fuse.
7. Contact an Authorized Service Dealer.
1. The engine load is excessive.
1. Reduce the ground speed.
2. The air cleaner is dirty.
3. The oil level in the crankcase is low.
4. The cooling fins and air passages
above the engine are plugged.
5. The vent hole in the fuel cap is plugged.
6. Dirt is in the fuel filter.
7. Dirt, water, or stale fuel is in the fuel
system.
2. Clean the air cleaner element.
3. Add oil to the crankcase.
4. Remove the obstruction from the
cooling fins and air passages.
5. Clean or replace the fuel cap.
6. Replace the fuel filter.
7. Contact an Authorized Service Dealer.
1. The engine load is excessive.
1. Reduce the ground speed.
2. The oil level in the crankcase is low.
3. The cooling fins and air passages
above the engine are plugged.
2. Add oil to the crankcase.
3. Remove the obstruction from the
cooling fins and air passages.
1. The by pass valve is not closed tight.
1. Tighten the by pass valve.
2. The drive or pump belt is worn, loose
or broken.
3. The drive or pump belt is off a pulley.
4. The idler spring is broken or missing.
5. The hydraulic fluid level is low or too
hot.
2. Change the belt.
3. Change the belt.
4. Replace the spring.
5. Add hydraulic fluid to the reservoir or
let it cool down.
1. The cutting blade(s) is/are bent or
unbalanced.
1. Install new cutting blade(s).
2. The blade mounting bolt is loose.
3. The engine mounting bolts are loose.
4. The engine pulley, idler pulley, or blade
pulley is loose.
5. The engine pulley is damaged.
6. The blade spindle is bent.
7. The motor mount is loose or worn.
2. Tighten the blade mounting bolt.
3. Tighten the engine mounting bolts.
4. Tighten the appropriate pulley.
63
5. Contact an Authorized Service Dealer.
6. Contact an Authorized Service Dealer.
7. Contact an Authorized Service Dealer.
Problem
Uneven cutting height.
The cutting blades do not rotate.
Possible Cause
Corrective Action
1. The cutting blade(s) is/are not sharp.
1. Sharpen the blade(s).
2. The cutting blade(s) is/are bent.
3. The mower deck is not level.
4. The underside of mower is dirty.
5. The tire pressure is not correct.
6. The blade spindle is bent.
2. Install new cutting blade(s).
3. Level the mower deck from side-to-side
and front-to-rear.
4. Clean the underside of the mower.
5. Adjust the tire pressure.
6. Contact an Authorized Service Dealer.
1. The drive belt is worn, loose or broken.
1. Check the belt tension.
2. The drive belt is off pulley.
2. Install the drive belt and check
adjusting shafts and belt guides for
correct position.
3. Install a new mower deck belt.
3. The mower deck belt is worn, loose or
broken.
4. The mower deck belt came off a pulley.
5. The idler spring is broken or missing.
64
4. Install mower deck belt and check the
idler pulley, idler arm and spring for the
correct position and function.
5. Replace the spring.
Schematics
g012068
Wire Diagram (Rev. A)
65
Notes:
66
International Distributor List
Distributor:
Atlantis Su ve Sulama Sisstemleri Lt
Balama Prima Engineering Equip.
B-Ray Corporation
Casco Sales Company
Ceres S.A.
CSSC Turf Equipment (pvt) Ltd.
Cyril Johnston & Co.
Equiver
Femco S.A.
G.Y.K. Company Ltd.
Geomechaniki of Athens
Guandong Golden Star
Hako Ground and Garden
Hako Ground and Garden
Hayter Limited (U.K.)
Hydroturf Int. Co Dubai
Hydroturf Egypt LLC
Ibea S.P.A.
Irriamc
Irrigation Products Int’l Pvt Ltd.
Jean Heybroek b.v.
Lely (U.K.) Limited
Maquiver S.A.
Maruyama Mfg. Co. Inc.
Metra Kft
Mountfield a.s.
Munditol S.A.
Oslinger Turf Equipment SA
Oy Hako Ground and Garden Ab
Parkland Products Ltd.
Prochaska & Cie
RT Cohen 2004 Ltd.
Riversa
Roth Motorgerate GmBh & Co.
Sc Svend Carlsen A/S
Solvert S.A.S.
Spypros Stavrinides Limited
Surge Systems India Limited
T-Markt Logistics Ltd.
Toro Australia
Toro Europe BVBA
Country:
Turkey
Hong Kong
Korea
Puerto Rico
Costa Rica
Sri Lanka
Northern Ireland
Mexico
Guatemala
Japan
Greece
China
Sweden
Norway
United Kingdom
United Arab Emirates
Egypt
Italy
Portugal
India
Netherlands
United Kingdom
Colombia
Japan
Hungary
Czech Republic
Argentina
Ecuador
Finland
New Zealand
Austria
Israel
Spain
Germany
Denmark
France
Cyprus
India
Hungary
Australia
Belgium
Phone Number:
90 216 344 86 74
852 2155 2163
82 32 551 2076
787 788 8383
506 239 1138
94 11 2746100
44 2890 813 121
52 55 539 95444
502 442 3277
81 726 325 861
30 10 935 0054
86 20 876 51338
46 35 10 0000
47 22 90 7760
44 1279 723 444
97 14 347 9479
202 519 4308
39 0331 853611
351 21 238 8260
86 22 83960789
31 30 639 4611
44 1480 226 800
57 1 236 4079
81 3 3252 2285
36 1 326 3880
420 255 704 220
54 11 4 821 9999
593 4 239 6970
358 987 00733
64 3 34 93760
43 1 278 5100
972 986 17979
34 9 52 83 7500
49 7144 2050
45 66 109 200
33 1 30 81 77 00
357 22 434131
91 1 292299901
36 26 525 500
61 3 9580 7355
32 14 562 960
374-0269 Rev A
The Toro Total Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company, pursuant to
an agreement between them, jointly promise to the original purchaser
to repair the Toro Products listed below if defective in materials or
workmanship.
2.
Bring the product and your proof of purchase (sales receipt) to the
Service Dealer.
3.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
RLC Customer Care Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
001-952-948-4650
The following time periods apply from the date of purchase by the original
owner:
Products
Mid-Size Walk-Behind Mowers
•Battery
•Attachments
Warranty Period
2 years**
2 years
2 years
Grand StandTM Mowers
•Engine
•Frame
•Battery
•Attachments
5 years or 1,200 hours*
2 years**
Lifetime (original owner only)***
1 year
1 year
Z Master® Z400, Z500 Mowers
•Engine
•Frame
•Battery
•Attachments
4 years or 1,200 hours*
2 years**
Lifetime (original owner only)***
1 year
1 year
Z Master® G3 Mowers
•Engine
•Frame
•Battery
•Attachments
5 years or 1,200 hours*
2 years**
Lifetime (original owner only)***
1 year
1 year
*Whichever occurs first.
See attached Distributor List.
Owner Responsibilities
You must maintain your Toro Product by following the maintenance
procedures described in the Operator’s Manual. Such routine
maintenance, whether performed by a dealer or by you, is at your expense.
Items and Conditions Not Covered
There is no other express warranty except for special emission
system and engine warranty coverage on some products.
This express warranty does not cover the following:
•
Cost of regular maintenance service or wear parts, such as filters,
fuel, lubricants, tune-up parts, blade sharpening, brake and clutch
adjustments.
•
Any product or part which has been altered or misused and requires
replacement or repair due to normal wear, accidents, or lack of
proper maintenance.
•
Repairs necessary due to improper fuel, contaminants in the fuel
system, or failure to properly prepare the fuel system prior to any
period of non-use over three months.
•
All repairs covered by these warranties must be performed by an
Authorized Toro Service Dealer using Toro approved replacement
parts.
**Some engines used on Toro LCE Products are warranted by the engine manufacturer.
***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form the
tractor structure that other components such as the engine are secured to, cracks or breaks in
normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame
failure due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.
This warranty includes the cost of parts and labor, but you must pay
transportation costs.
Instructions for Obtaining Warranty Service
Landscape
Contractor
Equipment (LCE)
General Conditions
The purchaser is covered by the national laws of each country. The rights
to which the purchaser is entitled with the support of these laws are not
restricted by this warranty.
If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:
1.
Contact your seller to arrange service of the product. If for any reason
it is impossible for you to contact your seller, you may contact any
Toro Authorized Distributor to arrange service.
374-0272 Rev A
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