Form No. 3437-336 Rev B Z Master® Professional 2000 Series Riding Mower with 48in, 52in, or 60in TURBO FORCE® Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 74490—Serial No. 74491—Serial No. 74492—Serial No. 74493—Serial No. 74494—Serial No. 74495—Serial No. 74496—Serial No. 74497—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 ....................................................................... 5 Safety Alert Symbol ............................................ 5 General Safety ................................................... 5 Slope Indicator ................................................... 6 Safety and Instructional Decals .......................... 7 Product Overview ................................................... 14 Controls ...........................................................
Replacing the Emissions-Air Intake Filter.............................................................. 51 Fuel System Maintenance ................................... 51 Replacing the Fuel Filter ................................... 51 Servicing the Fuel Tank..................................... 52 Electrical System Maintenance ........................... 52 Electrical System Safety ................................... 52 Servicing the Battery......................................... 52 Servicing the Fuses ..
General Safety Safety This machine is capable of amputating hands and feet and of throwing objects. Toro designed and tested this lawn mower to offer reasonably safe service; however, failure to comply with safety instructions may result in injury or death. This machine has been designed in accordance with ANSI standard B71.4-2017.
Slope Indicator g011841 Figure 6 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. This mark indicates that 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 109-6014 1. Traction belt routing decal116-5610 116-5610 1. Hour meter 2. Power take-off (PTO) 4. Neutral 5. Operator presence switch 3. Parking brake 6. Battery decal112-3858 112-3858 1. Read the Operator's Manual. 3. Remove the key before adjusting the height of cut. 2. Read the Operator's Manual before performing maintenance. 4. Height-of-cut settings decal112-9028 decal116-8588 112-9028 116-8588 1. Warning—stay away from moving parts; keep all guards and shields in place. 1.
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. decal117-1194 117-1194 1. Belt routing 2. Engine decal133-8062 133-8062 decal126-4784 126-4784 1. Height of cut decal117-3848 117-3848 1. Thrown object hazard—keep bystanders away. 2. Thrown object hazard, raised deflector—do not operate without the deflector, discharge cover, or grass collection system in place. 3.
decal126-9939 126-9939 1. Read the Operator’s Manual 2. Fill to bottom of filler neck; warning–do not overfill the tank Decal 131-1097 is for machines with Toro engines only. decal136-8992 136-8992 3. Fuel—empty 1. Fuel—full 2. Fuel—50% decal131-1097 131-1097 1. Oil drain decal136-9024 136-9024 10 4. Grease point 1. Read the Operator’s Manual before performing maintenance. 2. Operating hours 5. Hydraulic-fluid level 3. Engine-oil level 6.
decalptosymbols PTO Switch Symbols 1. PTO–disengage 2. PTO–engage decal126-6183 126-6183 1. Traction control 2. Fast 3. Slow decaltransportlock Transport Lock 1. Height of cut 4. Neutral 5. Reverse 2. Pull up to unlock the transport lock. decal137-9240 137-9240 1. Choke 2. Work light decal126-6194 126-6194 1. Traction control 2. Fast 3. Slow 4. Neutral 5. Reverse 11 3. Fast 4.
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. Decal 126-8383 is for machines without MyRide only.
decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in the conditions on that day and at that site.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g227688 Figure 7 1. Height-of-cut deck-lift pedal 7. Shock assembly 2. Height-of-cut positions 8. Seat belt 3. Transport lock 9. Fuel cap 4. Controls 10. Parking-brake lever 5. Motion-control levers 6. Roll bar 11. Mower deck 12. Caster wheel g271171 Figure 8 1. Position for optional power 5. Blade-control switch (power takeoff) point 2. Choke control 6.
Hour Meter Fuel-Shutoff Valve 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 9). Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 34). g187133 Figure 9 1. Safety-interlock symbols 3. Battery light 2.
Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation Use extreme care when handling fuel. Note: Determine the left and right sides of the machine from the normal operating position. DANGER In certain conditions gasoline is extremely flammable and vapors are explosive. Before Operation A fire or explosion from gasoline can burn you, others, and cause property damage. Before Operation Safety • Fill the fuel tank outdoors on level ground, in an open area, when the engine is cold. Wipe up any gasoline that spills.
To help prevent fires: DANGER • Keep engine and engine area free from In certain conditions during fueling, static electricity can be released causing a spark which can ignite gasoline vapors. A fire or explosion from gasoline can burn you and others and cause property damage. • Always place gasoline containers on the ground away from your vehicle before filling.
Breaking in a New Machine the chance of varnish deposits in the fuel system, use fuel stabilizer at all times. New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance. Filling the Fuel Tank 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4.
Using the Safety-Interlock System WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine. Understanding the Safety-Interlock System The safety-interlock system is designed to prevent the engine from starting unless the following occurs: • The parking brake is engaged.
Positioning the Seat Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. 1. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the ON position. Try starting the engine; the engine should not start. 2. Sit on the seat, engage the parking brake, and move the blade-control switch (PTO) to the OFF position.
Adjusting the Rear-Shock Assemblies Machines with MyRide™ Suspension System Only 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. g227752 The slots for the rear-shock assemblies have detent positions for reference. You can position the rear-shock assemblies anywhere in the slot, not just in the detent positions.
Using Attachments and Accessories WARNING Engine exhaust contains carbon monoxide, which is an odorless deadly poison that can kill you. Use only Toro approved attachments and accessories. If you add more than 1 accessory mount kit (i.e., bucket kit or universal mount kit) to both of the locations shown in Figure 17, add a front weight kit. Contact an Authorized Service Dealer for the front weight kit.
– Be alert and turn the machine off if children enter the area. WARNING Hands, feet, hair, clothing, or accessories can become entangled in rotating parts. Contact with the rotating parts can cause traumatic amputation or severe lacerations. – Do Not operate the machine without guards, shields, and safety devices in place and working properly. – Keep hands, feet, hair, jewelry, or clothing away from rotating parts.
Rollover Protection System (ROPS) Safety A Rollover Protection System (roll bar) is installed on the machine. WARNING There is no rollover protection when the roll bar is down. Wheels dropping over edges, ditches, steep banks, or water can cause rollovers, which may result in serious injury, death or drowning. • Do Not remove the ROPS. • Keep the roll bar in the raised and locked position and use seat belt. g221745 Figure 18 • Lower the roll bar only when absolutely necessary. 1.
Disengaging the Parking Brake Entering the Operator’s Position Use the mower deck as a step to get into the operator’s position (Figure 19). g192635 g029797 Figure 21 Figure 19 1. Step here. Operating the Parking Brake Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface.
Operating the Mower Operating the Choke Blade-Control Switch (PTO) Use the choke to start a cold engine. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) 1. Pull up the choke knob to engage the choke before using the key switch (Figure 25). 2. Push down the choke knob to disengage the choke after the engine has started (Figure 25).
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. Note: Refer to Figure 42 to determine which engine you have. 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 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 29 g037049 Figure 28 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 the Machine The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves. The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance.
Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf.
4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, and insert the pin (Figure 33). Adjusting the Anti-Scalp Rollers 5. Push on the deck lift, pull up on the transport lock knob, and slowly lower the mower deck. Whenever you change the height of cut, adjust the height of the anti-scalp rollers. Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas. 1.
Operating Tips drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower deck in uncut grass.
Using the Drive-Wheel Release Valves Using the Fuel-Shutoff Valve Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 35). WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Ensure that the fuel-shutoff valve is open when starting the engine. 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 37). 4. Back the machine up the ramp (Figure 38). g028043 Figure 38 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 WARNING Removal or modification of original equipment, parts and/or accessories may alter the warranty, controllability, and safety of the machine. Unauthorized modifications to the original equipment or failure to use original Toro parts could lead to serious injury or death. Unauthorized changes to the machine, engine, fuel or venting system, may violate applicable safety standards such as: ANSI, OSHA and NFPA and/or government regulations such as EPA and CARB.
• Keep hands and feet away from moving parts. • Use jack stands to support the machine and/or If possible, Do Not make adjustments with the engine running. If the maintenance or adjustment procedure require the engine to be running and components moving, use extreme caution. components when required. CAUTION Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous.
Maintenance Service Interval Maintenance Procedure Every 250 hours • For Kawasaki engines—replace the primary air filter (more often in dirty or dusty conditions). • For Kawasaki engines—check the safety air filter (more often in dirty or dusty conditions). • For Toro engines—replace the air filter (more often in dirty or dusty conditions). • After the initial change—change the hydraulic-system filters and fluid when using Mobil 1 15W50 fluid.
Greasing the Caster-Wheel Hubs 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. Service Interval: Yearly 14. Insert the second bearing and new seal into the wheel. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 15. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Engine Maintenance Servicing a Kawasaki® Engine Engine Safety This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 43, you have a Kawasaki engine. • Shut off the engine before checking the oil or adding oil to the crankcase. Important: Refer to your engine owner’s manual • Keep your hands, feet, face, clothing, and other for additional maintenance procedures. body parts away the muffler and other hot surfaces.
3. Carefully slide the primary filter over the safety filter (Figure 44). Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Important: Do not press on the soft, inside area of the filter. 4. g001883 Figure 44 1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch 4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 44).
Servicing the Engine Oil 3. Service Interval: Before each use or daily To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 46). Every 100 hours (more often in dirty or dusty conditions). Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) g036856 Crankcase Capacity: 1.
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 47). 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 48). g036856 g235264 Figure 48 7. Start the engine and drive to a flat area. 8. Check the oil level again.
Servicing the Spark Plug(s) Service Interval: Every 100 hours Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary. g036856 Type of Spark Plug: NGK® BPR4ES or equivalent Air Gap: 0.75 mm (0.03 inch) Removing the Spark Plug(s) 1.
Servicing a Toro Engine This section is only for machines with Toro engines. If your engine looks like the one shown in Figure 53, you have a Toro engine. g206628 Figure 51 Installing the Spark Plug(s) g296342 Figure 53 Servicing the Air Cleaner Service Interval: Every 250 hours—For Toro engines—replace the air filter (more often in dirty or dusty conditions). Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.
Servicing the Engine Oil Service Interval: Before each use or daily—For Toro engines—check the engine-oil level. After the first 5 hours/After the first month (whichever comes first)—For Toro engines—change the engine oil and filter. Every 100 hours or yearly, whichever comes first—For Toro engines—change the engine oil and oil filter (more often in dirty or dusty conditions). Engine-Oil Specifications g230914 Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Figure 54 1. Air-cleaner body 3.
g027799 g235263 Figure 56 Changing the Engine Oil and Oil Filter 1. Park the machine on a level surface to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) and engage the parking brake. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Drain the oil from the engine.
5. Change the engine-oil filter (Figure 58). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g235264 Figure 59 7. Dispose of the used oil at a recycling center. Servicing the Spark Plug(s) Service Interval: Every 100 hours or yearly, whichever comes first—For Toro engines—check the spark plug(s). Every 200 hours/Every 2 years (whichever comes first)—For Toro engines—replace the spark plug(s). g027477 Figure 58 6.
Installing the Spark Plug(s) g036857 g027478 Figure 60 g027960 Figure 62 Checking the Spark Plug(s) 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. Cleaning the Blower Housing If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester 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. Service Interval: Every 50 hours WARNING Hot exhaust-system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials, resulting in personal injury or property damage.
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.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the battery as shown in Figure 64. 4. Install the battery in the machine and connect the battery cables; refer to Installing the Battery (page 54). Note: Do not run the machine with the battery disconnected; electrical damage may occur. g036853 g000960 Figure 65 g036855 Figure 64 Charging the Battery WARNING Charging the battery produces gasses that can explode.
Installing the Battery Servicing the Fuses 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 64). 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 72 1. Cotter pin 3. Brake linkage shaft 2. Parking brake 7. Check both spring lengths as shown in Figure 73. If an adjustment is necessary, turn the top nut clockwise to shorten the spring and counterclockwise to lengthen it. g036100 Figure 73 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 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
9. Install the belt covers (Figure 77). 6. Remove the idler spring from the post (Figure 79). 7. Remove the existing belt from the hydraulic-pump-drive pulleys and the engine pulley. 8. Install the new belt around the engine pulley and the 2 hydraulic-pump pulleys (Figure 79). g027730 Figure 77 Replacing the Hydraulic Pump-Drive Belt 1. g036859 Figure 79 Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
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 62). 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Loosen the upper bolt holding the control lever to the control arm shaft. 4.
Adjusting the Motion-Control Linkage 11. Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse (Figure 82). 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.
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.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Allow the engine to cool. 4. Locate the filter and guards on each transaxle-drive system (Figure 84). 5. Remove the 3 screws securing the filter guard and guard (Figure 84). 4. Install the filter guards over each filter that you previously removed. 5. Use the 3 screws to secure the filter guards. 6. Verify that the vent plugs are removed before adding the fluid. 7.
2. 3. Start the engine, move the throttle control ahead to the 1/2 throttle position, and disengage the parking brake. A. Move the bypass levers into the pushing the machine position. With the bypass valves open and the engine running, slowly move the motion-control levers in both forward and reverse 5 or 6 times. B. Move the bypass levers into the operating the machine position. C.
Mower Deck Maintenance Blade Safety A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. 1. Cutting edge 3. Wear/slot forming • Inspect the blades periodically for wear or damage. 2. Curved area 4. Crack g006530 Figure 87 • Use care when checking the blades.
g014973 g014973 Figure 89 Figure 91 1. Blade (in position for measuring) 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Measured distance between blade and the surface (A) 2. Level surface 3. Second measured distance between blade and surface (B) 4. Rotate the same blade 180 degrees so that the opposing cutting edge is now in the same position (Figure 90). A.
g000553 Figure 94 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 92). Important: The curved part of the blade must point upward toward the inside of the mower to ensure proper cutting. g017443 Figure 92 2. 4. Blade bolt 5. Spindle shaft 1. Sail area of the blade 2. Blade Note: Install the curved-washer cone toward 3. Curved washer the bolt head. 3. Sharpening the Blades 1.
4. Position the mower deck in the transport-lock position. A. Raise the deck to the transport position (12.7 cm or 5 inches). 5. Carefully rotate the blades from side to side. B. 6. Measure between the blade tip and the flat surface (Figure 95). If both measurements are not within 5 mm (3/16 inch), adjust the leveling; continue with this procedure. Slowly loosen the adjusting screw on the lift-assist spring until you can remove the screw (see Figure 97). Note: Save the screw for installation.
g038090 Figure 98 Bottom view 1. Block—7.3 cm (2.87 inches) 2. Welds g035851 Figure 99 Block Height and Rake Table Deck Size Front Block Height Rake All mower decks 7.3 cm (2.87 inches) 4.8 to 6.4 mm (3/16 to 1/4 inch) 13. Carefully rotate the blades side to side (Figure 95). 14. Loosen the locknuts (Figure 99) on all 4 corners and ensure that the mower deck is sitting securely on all 4 blocks. 15. 16.
Removing the Mower Deck Replacing the Grass Deflector Before servicing or removing the mower deck, lock out the spring-loaded deck arms. 1. WARNING 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. Place the height-adjustment pin in the 7.6 cm (3 inch) cutting-height location. 4. Remove the belt covers. 5.
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.
Storage 13. Storage Safety Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: A. • Shut off the engine, remove the key, wait for all moving parts to stop, and allow the machine to cool before storing it. • Do not store the machine or fuel near flames or drain the fuel indoors. Add a petroleum-based stabilizer/conditioner to fuel in the tank. Follow mixing instructions from the stabilizer manufacturer.
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.
g037072 Wire Diagram—Kawasaki Engines (Rev.
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
