Form No. 3424-594 Rev A 48in, 52in, or 60in TITAN® HD 1500 Series Riding Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 74450—Serial No. 74451—Serial No. 74452—Serial No. 74463—Serial No. 74465—Serial No. 74466—Serial No. 74467—Serial No. 74470—Serial No. 74471—Serial No. 74472—Serial No. 78450—Serial No. 78472—Serial No.
It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.
Contents Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator ................................................... 5 Safety and Instructional Decals .......................... 6 Product Overview ................................................... 15 Controls ........................................................... 15 Specifications ..................................................
Safety Replacing the Emissions-Air Intake Filter.............................................................. 57 Fuel System Maintenance ................................... 57 Replacing the Fuel Filter ................................... 57 Servicing the Fuel Tank..................................... 58 Electrical System Maintenance ........................... 58 Electrical System Safety ................................... 58 Servicing the Battery.........................................
Slope Indicator g011841 Figure 5 You may copy this page for personal use. 1. The maximum slope you can operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decaloemmarkt Manufacturer's Mark decal106-5517 1. Indicates the blade is identified as a part from the original machine manufacturer. 106-5517 1. Warning—do not touch the hot surface. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6.
decal109-6014 decal112-3858 109-6014 112-3858 1500 and 2000 Series Side Discharge Machines Only 1. Read the Operator's Manual. 3. Remove the key before adjusting the height of cut. 2. Read the instructions before servicing or performing maintenance. 4. Height-of-cut settings. decal112-9028 112-9028 decal109-6035 109-6035 2500 Series Side Discharge Machines Only 1. Warning—stay away from moving parts; keep all guards in place. decal115-9625 115-9625 1.
decal116-5610 116-5610 1. Hour meter 2. Power takeoff (PTO) 4. Neutral 5. Operator-presence switch 3. Parking brake 6. Battery decal117-1194 117-1194 1500 and 2000 Series Side-Discharge Machines Only 1. Engine decal133-8062 133-8062 decal116-8588 116-8588 1. Read the Operator’s Manual. 2. Rotate the drive release knob to loosen, slide the knob, and tighten. decal117-3848 3. Push the machine. 117-3848 1. Thrown object hazard—keep bystanders a safe distance away from the machine. 2.
decal126-0768 126-0768 Rear Discharge Units Only decal126-4784 126-4784 1. Height of cut decal126-4363 126-4363 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. Shut off the engine and remove the key before adjusting, servicing or cleaning the machine. decal126-6599 126-6599 Rear Discharge Units 1. Thrown objects hazard—keep bystanders a safe distance away from the machine. 9 2. Cutting/dismemberment of hand—stay away from moving parts; keep all guards and shields in place.
decal126-8161 126-8161 1. Read the Operator’s Manual. 2. Slide seat forward 3. Press down on latch to unlock seat 4. Rotate seat decal127-6662 127-6662 Rear Discharge Mowers Only 1. Attention—read the Operator's Manual. 3. Remove the bolt by turning it counter clockwise. 2. Remove the nut by turning it clockwise. decal126-9939 126-9939 1. Read the Operator’s Manual. 2. Fill to the bottom of the filler neck; warning—do not overfill the tank. decal131-1097 131-1097 Toro Engines Only 1.
decalptosymbols PTO Switch Symbols 1. PTO–disengage 2. PTO–engage decaltransportlock decal136-8992 Transport Lock 136-8992 Machines with MyRide Only 1. Height of cut 2. Pull up to unlock the transport lock. 3. Fuel—empty 1. Fuel—full 2. Fuel—50% decal136-9024 136-9024 4. Grease point 1. Read the Operator’s Manual before performing maintenance. 2. Operating hours 5. Hydraulic-fluid level 1. Machine speed 4. Neutral 3. Engine-oil level 6. Tire pressure 2. Fast 3. Slow 5.
decalmotioncntrlrh-126-6183 Right Motion Control 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse decal126-8151 126-8151 1. Read the instructions before servicing or performing maintenance on the machine. 2. Time interval 4. Refer to the Operator's Manual for grease instructions. 5. Check the hydraulic-fluid level and refer to the Operator's Manual for further instructions. 6. Check the tire pressure. 3. Check the oil level.
decal126-8383 126-8383 Machines without MyRide Only Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
decal132-0871 132-0871 Machines with MyRide Only Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
Key Switch Product Overview The key switch, used to start and shut off the engine, has 3 positions: OFF, RUN, and START . Refer to Starting the Engine (page 27). Choke Control Use the choke control to start a cold engine. Throttle Control The throttle controls the engine speed, and it has a continuous-variable setting from the SLOW to FAST position (Figure 7). Blade-Control Switch (Power Takeoff) g227688 Figure 6 1. Height-of-cut deck-lift pedal 7. Shock assembly (machines with MyRide only) 2.
Battery-Indicator Light If you turn the ignition key to the ON position for a few seconds, the battery voltage displays 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 8). g187133 Figure 8 1. Safety-interlock symbols 3. Battery light 2. Hour meter Motion-Control Levers Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 7).
Specifications Note: Specifications and design are subject to change without notice.
Operation • Note: Determine the left and right sides of the machine from the normal operating position. Before Operation • Before Operation Safety • General Safety • Never allow children or untrained people to • • • • • • • operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. Become familiar with the safe operation of the equipment, operator controls, and safety signs.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh longer when used as directed by the fuel-stabilizer manufacturer • Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of fuel stabilizer/conditioner to the fuel.
Using the Rollover-Protection System (ROPS) WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. g036746 • Drive slowly and carefully.
Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily WARNING 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. If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. 1.
Adjusting the MyRide™ Suspension System Positioning the Seat The seat can move forward and backward (Figure 12). Position the seat where you have the best control of the machine and are most comfortable. The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable.
Using Attachments and Accessories Adjust the rear-shock assemblies (Figure 15). Use only Toro approved attachments and accessories. If more than one accessory-mount kit (i.e., bucket kit or universal mount kit) is added to any of the 4 locations shown in Figure 16, add a front-weight kit. Contact your Authorized Service Dealer for the front-weight kit. g227752 g037417 Figure 16 1. Add a front-weight kit when 2 or more accessory-mount kits are installed at these positions.
• Avoid mowing on wet grass. Reduced traction • • • • • • • • • • • • • • • • • hearing loss through extended periods of exposure. could cause the machine to slide. Ensure that all drives are in neutral, the parking brake is engaged, and you are in the operating position before you start the engine. Keep your hands and feet away from the cutting units. Keep clear of the discharge opening at all times. Look behind and down before backing up to be sure of a clear path.
Entering the Operator’s Position the machine and any hazard. Use a walk-behind machine or a hand trimmer to mow the grass in these areas. • Avoid starting, stopping, or turning the machine on Use the mower deck as a step to get into the operator’s position (Figure 19). slopes. Avoid making sudden changes in speed or direction; turn slowly and gradually. • Do not operate a machine under any conditions where traction, steering, or stability is in question.
Disengaging the Parking Brake Disengaging the Blade-Control Switch (PTO) g009174 Figure 23 Operating the Throttle You can move the throttle control between FAST and SLOW positions (Figure 24). g192635 Always use the FAST position when engaging the PTO. Figure 21 Operating the Mower Blade-Control Switch (PTO) The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.
Operating the Choke Starting the Engine Use the choke to start a cold engine. Note: A warm or hot engine may not require choking. 1. 2. Pull up the choke knob to engage the choke before using the key switch (Figure 25). Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
Shutting Off the Engine Shutting Off Kohler Engines Note: Refer to Figure 45 to determine which engine Let the engine idle at mid-throttle for 60 seconds before turning the switch off. you have. CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the key and engage the parking brake when leaving the machine unattended.
Shutting Off Toro Engines Using the Motion-Control Levers Note: Ensure the throttle is in the FAST position before shutting off the engine. c:\data\documentum\checkout\g004532 Figure 30 g037049 Figure 29 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3. Forward Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine to prevent fuel leakage. Engage the parking brake before transporting.
Driving Backward WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 32). • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged.
Adjusting the Height of Cut Adjusting the Height-of-Cut Pin Using the Transport Lock Adjust the height-of-cut from 38 to 127 mm (1-1/2 to 5 inches) in 6 mm (1/4 inch) increments by moving the height-of-cut pin into different hole locations. The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 33). 1. Move the transport lock to the LOCK position. 2.
3. Adjusting the Side Bumpers Adjust the anti-scalp rollers as shown in Figure 35 or Figure 36. Rear-Discharge Machines Only Install the side bumpers in the top holes when operating in a height of cut higher than 64 mm (2-1/2 inches) and in the center holes when operating in a height of cut lower than 64 mm (2-1/2 inches). Note: When the bumpers become worn, switch the bumpers to the opposite sides of the mower and flip them over. This allows you to use the bumpers longer before replacing them. 1.
Using the Side Discharge grass is sparse, or it is late fall when grass grows more slowly. The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Alternating the Mowing Direction Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.
Using the Drive-Wheel Release Valves After Operation After Operation Safety WARNING General Safety Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel release valves.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.
1. If using a trailer, connect it to the towing vehicle and connect the safety chains. 2. If applicable, connect the trailer brakes and lights. 3. Lower the ramp, ensuring that the angle between the ramp and the ground does not exceed 15 degrees (Figure 40). 4. Back the machine up the ramp (Figure 41). g028043 Figure 41 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • For Toro engines—change the engine oil and filter. After the first 75 hours • Change the hydraulic-system filters and fluid. Before each use or daily • • • • • • • • • • • • • • • Check the safety-interlock system. For Kawasaki engines—check the engine-oil level. For Kohler engines—check the air cleaner for dirty, loose, or damaged parts.
Maintenance Service Interval Maintenance Procedure Every 250 hours • For Kawasaki engines—replace the primary air filter (more often in dusty or sandy conditions). • For Kawasaki engines—check the safety air filter (more often in dusty or sandy conditions). • For Toro engines with a heavy-duty air cleaner—replace the air filter (more often in dusty or sandy conditions).
Lubrication by a safety device. Check their proper operation regularly. • Use only genuine Toro replacement parts. Greasing the Machine • Check the parking brake operation frequently. Adjust and service as required. Service Interval: Every 25 hours—Grease the front caster axles. (more often in dirty or dusty conditions). Every 50 hours—Grease the pump-idler pivot. Grease Type: No. 2 lithium or molybdenum grease 1.
Lubricating the Caster-Wheel Hubs approximately 3 mm (1/8 inch) from the outer surface of the spacer nut to the end of the axle inside the nut. 2500 Series Machines Only 11. Insert the assembled nut and axle into the wheel on the side with the new seal and bearing. Service Interval: Yearly—For 2500 Series machines—Lubricate the caster-wheel hubs. 12. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. 13.
Engine Maintenance Identifying the Engine Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 45). g231391 Figure 45 1. Kawasaki engine 3. Toro engine with standard air cleaner 2. Kohler engine 4. Toro engine with heavy-duty air cleaner • For Kawasaki engine maintenance, refer to Servicing a Kawasaki® Engine (page 41). • For Kohler engine maintenance, refer to Servicing a Kohler® Engine (page 46).
Servicing the Air Cleaner Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Service Interval: Every 250 hours—For Kawasaki engines—replace the primary air filter (more often in dusty or sandy conditions). 7. Every 250 hours—For Kawasaki engines—check the safety air filter (more often in dusty or sandy conditions).
Servicing the Engine Oil Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: 1.8 L (61 fl oz) without the oil filter; 2.1 L (71 fl oz) with the oil filter g036856 Viscosity: See the table below. g037096 Figure 48 Note: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.
3. Disengage the blade-control switch (PTO) and engage the parking brake. 4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Drain the oil from the engine (Figure 50). 6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 51). g036856 g027660 Figure 51 g027734 Figure 50 44 7. Start the engine and drive to a flat area. 8.
Changing the Engine-Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). Service Interval: Every 100 hours 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 43). 2. Change the engine-oil filter (Figure 52). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
Checking the Spark Plug Servicing a Kohler® Engine Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 56, you have a Kohler engine. Important: Refer to your engine owner’s manual If you see light brown or gray on the insulator, the engine is operating properly.
Servicing the Paper Element Removing the Elements 1. Rotate the latches outward. 2. Remove the cover to access the air-cleaner elements (Figure 57). 1. Gently tap the paper element to dislodge dirt. Note: Do not wash the paper element or use pressurized air, as this will damage the element. Note: Replace a dirty, bent, or damaged element. Handle the new element carefully; do not use if the sealing surfaces are bent or damaged. 2. Clean the air-cleaner base as required, and check the condition.
2. Changing the Engine Oil and the Engine-Oil Filter Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Service Interval: Every 100 hours—For Kohler engines—change the engine oil and the engine-oil filter. Note: Ensure that the engine is cool so that the oil has had time to drain into the sump. 3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 49).
g027517 Figure 63 7. g028127 Figure 62 6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 63). 49 Dispose the used oil at a recycling center.
Servicing the Spark Plug Service Interval: Every 200 hours—For Kohler engines—check the spark plug(s). Every 500 hours—For Kohler engines—replace the spark plug(s). The spark plug is RFI compliant; you can also use an equivalent plug. g206628 Figure 65 Type: Champion XC12YC Air Gap: 0.76 mm (0.03 inch) Installing the Spark Plug Removing the Spark Plug 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
Servicing a Toro Engine This section is only for machines with Toro engines. If your engine looks like 1 of the 2 engines shown in Figure 67, you have a Toro engine. g027800 g231404 Figure 67 1. Standard air cleaner 2. Heavy-duty air cleaner Servicing the Air Cleaner Engines with a Standard Air Cleaner Service Interval: Every 25 hours/Monthly (whichever comes first)—For Toro engines with a standard air cleaner—clean the air-cleaner foam element (more often in dusty, dirty conditions).
Servicing the Air Cleaner Servicing the Paper Element 1. Gently tap the paper element to dislodge dirt. Engines with a Heavy-Duty Air Cleaner Note: Do not wash the paper element or use Service Interval: Every 250 hours—For Toro engines with a heavy-duty air cleaner—replace the air filter (more often in dusty or sandy conditions). pressurized air, as this will damage the element. Note: Replace a dirty, bent, or damaged 2. element.
Installing the Filters 2. Important: To prevent engine damage, always operate the engine with the air filter and the cover installed. 1. Note: Ensure that the engine is cool so that the oil has had time to drain into the sump. If you are installing a new filter, check the filter for shipping damage. 3. Note: Do not use a damaged filter. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. To keep dirt, grass clippings, etc.
oil and oil filter (more often in dusty, dirty conditions). Note: Dispose of the used oil at a recycling center. 1. Park the machine on a level surface to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) and engage the parking brake. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. g027799 Drain the oil from the engine (Figure 74).
5. Change the engine-oil filter (Figure 75). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g193530 Figure 76 Servicing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first)—For Toro engines—check the spark plug(s). g027477 Figure 75 6. Every 200 hours/Every 2 years (whichever comes first)—For Toro engines—replace the spark plug(s).
Cleaning the Cooling System g027478 Figure 77 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air filter from the engine. 4. Remove the engine shroud. 5. To prevent debris entering the air intake, install the air filter to the filter base. 6. Clean debris and grass from the parts. 7.
Replacing the Emissions-Air Intake Filter Fuel System Maintenance Service Interval: Every 500 hours 1. DANGER Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the filter from the vent hose. 4. Insert a new filter into the end of the vent hose.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Charging the Battery WARNING Incorrectly removing the cables from battery could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Important: Always keep the battery fully charged (1.
Installing the Battery Servicing the Fuses 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 81). 2. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative (black) battery cable and ground wire to the negative (-) battery terminal. The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows check the component and circuit for a malfunction or short.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Checking the Roll-Bar Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. Ensure that the seat is secured to the machine.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open, flat area and move the motion-control levers to the NEUTRAL-LOCK position. Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) 3. Move the throttle midway between the FAST and SLOW positions. 4. Move both motion-control levers forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks. 6.
Cooling System Maintenance Brake Maintenance Service Interval: Before each use or daily Service Interval: Every 500 hours Adjusting the Parking Cleaning the Engine Screen Brake Note: Perform this procedure whenever you remove Before each use or daily or replace a brake component. Before each use remove any buildup of grass, dirt, or other debris from the engine screen, engine exhaust, and the area around the engine.
9. Rotate the brake-linkage shaft until the end aligns with the hole in the lever. • Shorten the linkage by turning it clockwise. • Lengthen the linkage by turning it counterclockwise. g036752 Figure 89 1. Cotter pin 3. Brake linkage shaft 2. Parking brake 7. Check both spring lengths as shown in Figure 90. If an adjustment is necessary, turn the top nut clockwise to shorten the spring and counterclockwise to lengthen it. g036100 Figure 90 1. Top nut 3. 44 mm (1-3/4 inches) 2. Spring 8.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Replacing the Mower Belt for Side-Discharge Mower Decks 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
Replacing the Mower Belt for Rear-Discharge Mower Decks Replacing the Counter-Rotating Belt g036865 Figure 94 2500 Series Mower Decks 1. Clutch pulley 4. Ratchet 2. Mower belt 5. Square hole in the idler arm for the ratchet 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
9. Remove the belt from the remaining pulleys (Figure 96). 10. Route the new belt abound the mower pulleys. 11. Using the ratchet in the square hole, remove the tension on the spring, and guide the new belt around the idler pulley (Figure 96). Replacing the Mower Belt 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Replacing the Hydraulic Pump-Drive Belt 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the mower belt; refer to Replacing the Mower Belt for Side-Discharge Mower Decks (page 65) or Replacing the Mower Belt for Rear-Discharge Mower Decks (page 66). 4.
Adjusting the Tilt Controls System Maintenance Adjusting the Control-Handle Position If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage (page 70). 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
Adjusting the Motion-Control Linkage Located on either side of the machine, below the seat, are the pump-control linkages. Rotating the end nut with a 1/2-inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only. 11. Adjust the pump-control-rod lengths by turning the nut in the appropriate direction until the wheels slightly creep in reverse (see Figure 104). 12.
Hydraulic System Maintenance Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.
4. Locate the filter and guards on each transaxle-drive system (Figure 106). 5. Remove the 3 screws securing the filter guard and guard (Figure 106). 7. Slowly pour the specified fluid through the expansion reservoir until fluid comes out of 1 of the vent-plug holes. 8. Install the vent plug. 9. Torque the plug to 20 N∙m (15 ft-lb). 10. Continue to add fluid through the expansion reservoir until fluid comes out of the remaining vent-plug hole on the second transmission. 11.
Mower Deck Maintenance Bleeding the Hydraulic System 1. Raise the rear of machine and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand.
g006530 Figure 109 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 111 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
g014973 Figure 113 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B) A. g017443 If the difference between A and B is greater than 3 mm (1/8 inch), replace the blade with a new blade; refer to Replacing the Blades for Side Discharge Mower Decks (page 75) or Replacing the Blades for Rear Discharge Mower Decks (page 75). Figure 114 1. Sail area of the blade 2. Blade 3.
3. Remove the right blade bolt (left-hand threaded bolt), curved washer, and blade from the spindle shaft (Figure 116). Note: Note the blade type and where each blade is installed. See Figure 116 for the correct position. g024248 Figure 116 g017443 1. Front of mower deck Figure 115 Left and Center Spindle Shown 1. Sail area of the blade 2. Blade 4. Counter-rotating blade 2. Right-hand threaded blade 5. Left-hand threaded blade bolts bolt 3. Regular blades 4. Blade bolt 5. Spindle shaft 3.
Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 117). g000553 Figure 118 1. Blade 3. 2. Balancer g229303 Repeat this procedure until the blade is balanced. Leveling the Mower Deck Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.
8. Set the anti-scalp rollers to top holes or remove them completely for this adjustment. 9. Place 2 blocks (see table below) under the rear edge of the cutting deck skirt; 1 on each side of the cutting deck (Figure 121). 10. Set the height-of-cut lever to the 3 inch (76 mm) position. 11. Place 2 blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets or welds. g035851 Figure 122 1. Locknuts 3. Deck hanger 2. Deck-lift arm 4. Chain 16.
Removing the Mower Deck 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Lower the height-of-cut lever to the lowest position. 4. Remove the hairpin cotter from the front support rod, and remove the rod from the deck bracket (Figure 123). g005077 Figure 124 1. Mower deck 2. Hanger bracket 3. Rear lift rod 7.
Cleaning Cleaning under the Mower Deck Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower deck to the TRANSPORT position. g015594 Figure 125 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 73). Storage Safety 13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. A. • Do not store the machine or fuel near flames or drain the fuel indoors. • Remove the key and store it in a safe place out of the reach of children.
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in the fuel system. The starter does not crank.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or broken. 3. The pump belt is off a pulley. 4. The idler spring is broken or missing. 5. The hydraulic fluid level is low or too hot. 2. Change the belt. 3. Change the belt. 4. Replace the spring. 5. Add hydraulic fluid to the reservoirs or let it cool down.
Schematics g018479 Wire Diagram—Toro Engines (Rev.
g036151 Wire Diagram—Kohler Engines (Rev.
g037072 Wire Diagram—Kawasaki Engines (Rev.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
