Form No. 3409-427 Rev B Z Master® Professional 5000 Series Riding Mower with 48in TURBO FORCE® Side Discharge Mower Model No. 74904—Serial No. 400000000 and Up Register at www.Toro.com.
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.
Contents Servicing the Spark Plug................................... 42 Checking the Spark Arrester ............................. 43 Fuel System Maintenance ................................... 44 Servicing the Electronic Fuel-Injection System.......................................................... 44 Replacing the Low-Pressure Fuel Filter.............................................................. 44 Servicing the High-Pressure Fuel Filter............. 44 Servicing the Fuel Tank........................
Safety Schematics ............................................................. 74 This machine has been designed in accordance with ANSI B71.4-2012. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
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.
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. decal58-6520 58-6520 decal106-2655 1. Grease 106-2655 1. Warning-do not touch or approach moving belts; remove the ignition key and read the instructions before servicing or performing maintenance. decal93-7818 93-7818 1.
decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal107-3069 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 seat belt when the roll bar is down. 3.
decal116-5988 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged decal116-8726 116-8726 decal136-5508 136-5508 1. Read the Operator’s Manual for the recommended hyraulic fluid. 1. Belt routing decal116-1716 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 9. Neutral 10. Operator-presence switch decal117-0346 117-0346 1.
decal126-2055 126-2055 1. Wheel lug nut torque 129 N∙m (95 ft-lb) (4x) 2. Wheel hub nut torque 319 N∙m (235 ft-lb) 3. Read and understand the Operator’s Manual before performing any maintenance, check torque after first 100 hours then every 500 hours thereafter. decal117-3848 117-3848 1. Thrown object hazard—keep bystanders a safe distance away from the machine. 2. Thrown object hazard, mower-do not operate the machine without the deflector, discharge cover, or grass collection system in place. 3.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery decal127-0326 127-0326 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before performing maintenance or servicing the machine. 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4.
decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
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 6). Fuel Gauge The fuel gauge is located with the hour meter, and the bars light up when the ignition switch is in the ON position (Figure 6). The indicator light appears when the fuel level is low (approximately 1 gallon remaining in the fuel tank).
Blade-Control Switch (Power Takeoff) Specifications The blade-control switch (PTO) engages and disengages power to the mower blades (Figure 5). change without notice. Note: Specifications and design are subject to Width 48-inch Deck Ignition Switch Use this switch to start the mower engine. It has 3 positions: START , RUN, and OFF. Motion-Control Levers Without Deck 116.1 cm (45.7 inches) Deflector Up 137.2 cm (54 inches) Deflector Down 161.4 cm (63.
Operation containers on the ground, away from your vehicle before filling. • Remove the equipment from the truck or trailer Note: Determine the left and right sides of the and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than a fuel-dispenser nozzle. machine from the normal operating position. Before Operation • Do not operate the machine without the entire exhaust system in place and in proper working condition.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh during storage of 90 days or less (drain the fuel tank when storing the machine for more than 90 days) • 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. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits.
Think Safety First CAUTION This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Wear hearing protection when operating this machine. Operating the machine on wet grass or steep slopes can cause sliding and loss of control.
to the NEUTRAL-LOCK position. Try starting the engine; the engine should not start. Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. To adjust the seat, move the lever sideways to unlock the seat (Figure 12). g009181 Figure 11 1.
Changing the Seat Suspension During Operation During Operation Safety The seat adjusts to provide a smooth and comfortable ride. Position the seat where you are most comfortable. General Safety • The owner/operator can prevent and is responsible To adjust, turn the knob in front either direction to provide the best comfort (Figure 14). • • • • g019768 • Figure 14 1. Seat-suspension knob • • • • • • • • • • • 19 for accidents that may cause personal injury or property damage.
Operating the Parking Brake • Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following: – Stop the machine on level ground. Always engage the parking brake when you stop the machine or leave it unattended. – Disengage the power take-off and lower the attachments. Engaging the Parking Brake – Engage the parking brake. – Shut off the engine and remove the key. WARNING – Wait for all moving parts to stop.
Operating the Mower Blade-Control Switch (PTO) The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) g008946 Figure 19 Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts. Operating the Ignition Switch 1. Turn the ignition key to the START position (Figure 20). Note: When the engines starts, release the key.
Shutting Off the Engine Starting and Shutting Off the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Starting the Engine Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow these instructions can burn out the starter motor.
Using the Motion-Control Levers 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. • Slow the machine down before making sharp turns. g004532 Figure 23 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3. Forward Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle.
Driving Forward Driving Backward Note: The engine stops when you move the traction-control with the parking brake engaged. To stop, pull the motion-control levers to the NEUTRAL position. 1. Disengage the parking brake; refer to Disengaging the Parking Brake (page 20). 2. Move the levers to the center, unlocked position. 3. To go forward, slowly push the motion-control levers forward (Figure 24). 1. Move the levers to the center, unlocked position. 2.
Stopping the Machine Adjusting the Height of Cut To stop the machine, move the traction-control levers to neutral, and then move them to the locked position, disengage the blade-control switch (PTO), and turn the ignition key to the OFF position. Using the Transport Lock The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and a UNLOCK position for the transport position (Figure 26).
Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. 1. Move the transport lock to the lock position. 2. Push on the deck-lift pedal with your foot, and raise the mower deck to the transport position (also the 140 mm (5-1/2 inches) cutting height position) as shown in Figure 27. 3.
g027727 Figure 31 g000944 Figure 30 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt Positioning the Flow Baffle 3. Bushing The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. Adjusting the Flow Baffle Cam Locks Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. This procedure is applicable only to machines with the flow-baffle locks.
Position B Use this position when bagging. Always align it with the blower opening. g005833 Figure 33 Position C This is the full open position.
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 in uncut grass.
Using the Drive-Wheel-Release Valves After Operation After Operation Safety General Safety WARNING • Clean grass and debris from the cutting units, • • • • • • Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. Shut off the fuel before storing or transporting the machine.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. 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, your family, pets, or bystanders avoid injury.
Loading the Machine Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back up the ramp and drive forward down the ramp (Figure 38). g028043 Figure 38 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. Important: Do not use narrow individual ramps for each side of the machine.
Maintenance Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 100 hours • Check the wheel lug-nut torque. • Check the wheel-hub slotted-nut torque. • Check the parking brake adjustment. After the first 250 hours • Change the hydraulic filters and hydraulic fluid when using any type of fluid.
Important: Refer to your engine operator's manual for additional maintenance procedures. 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 before you do any maintenance. Pre-Maintenance Procedures by a safety device. Check their proper operation regularly.
Lubrication Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 general-purpose lithium-based or molybdenum-based grease 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. g017050 Figure 41 Clean the grease fittings with a rag.
4. Lubricating the Caster-Wheel Hubs Grease the drive belt idler arm (Figure 43). Service Interval: Yearly 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake. g009030 Figure 43 g006115 Figure 45 Remove the dust cap and adjust the caster pivots. 1. Seal guard Note: Keep the dust cap off until greasing is complete. Refer to Adjusting the Caster-Pivot Bearing (page 50). 2. Raise the mower for access. 3.
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. Insert the second bearing and new seal into the wheel. 14. 15. Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.
g012996 Figure 46 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch g012997 Figure 47 6. 7. 8. 1. Inner filter 2. Primary filter Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 47). 3. Air-cleaner cover Clean the inside of the air-cleaner cover with compressed air. 10. Gently slide the primary filter out of the air-cleaner body (Figure 47).
4. Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Servicing the Engine Oil Important: Do not press on the soft, inside area of the filter. Oil Capacity: with a filter change—1.9 L (64 oz); without a filter change—1.6 L (54 oz) Install the air-cleaner cover and secure the latches (Figure 47). Viscosity: See the table below.
Changing the Engine Oil Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions). Note: Dispose of the used oil at a recycling center. 1. g008804 Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. 2. 3. 4. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely.
5. Changing the Engine-Oil Filter 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). Service Interval: Every 200 hours Note: Change the engine-oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 40). 2. Change the engine-oil filter (Figure 52). g008804 g194610 Figure 51 6.
Servicing the Spark Plug Service Interval: Every 200 hours—Check, clean and regap the spark plug. 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(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary. g009922 Type : Champion® XC12YC, or equivalent Air Gap: 0.76 mm (0.030 inch) Removing the Spark Plug 1.
5. Installing the Spark Plug Install the left hydraulic-unit shroud (Figure 53). Tighten the spark plug(s) to 24.4 to 29.8 N-m (18 to 22 ft-lb). Checking the Spark Plug Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Set the gap to 0.76 mm (0.030 inches).
Fuel System Maintenance WARNING Fuel-system components are under high pressure. The use of improper components can result in system failure, gasoline leakage, and possible explosion. Use only approved fuel lines and fuel filters. Servicing the Electronic Fuel-Injection System g008963 Figure 57 This machine contains an electronic fuel-injection system. It controls the fuel flow under different operating conditions. 1. Fuel filter 2.
Removing the Battery Electrical System Maintenance WARNING Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine.
Installing the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 58). g000960 Figure 60 g032526 1. Positive battery post 3. Red (+) charger lead 2. Negative battery post 4. Black (-) charger lead Servicing the Fuses Figure 59 The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component/circuit for a malfunction or short. Charging the Battery 1.
Jump-Starting the Machine 1. vent caps on both batteries. Also ensure that the machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight. 3. CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure.
Drive System Maintenance Checking the Seat Belt g008804 Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of retractor and buckle. Replace the seat belt if it is damaged. Checking the Rollover Protection System (ROPS) Knobs g013117 Service Interval: Before each use or daily Figure 63 1. Engine block 7. 2. Negative (–) cable WARNING To avoid injury or death from rollover: keep the roll bar in the fully raised locked position and use the seat belt.
right T-slot until the machine tracks straight (Figure 65). 6. Tighten the stop plate (Figure 65). g027340 Figure 65 Left control lever shown 1. Control lever g008943 Figure 64 1. ROPS knob (locked position) 3. Stop plate 2. Bolt 3. Roll bar in the upright position 4. Roll bar in the folded 2.
g001055 Figure 66 Checking the Wheel-Lug Nuts Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb). g027341 Figure 67 1. Slotted nut Checking the Wheel-Hub Slotted Nut Adjusting the Caster-Pivot Bearing Service Interval: After the first 100 hours Every 500 hours Service Interval: Every 500 hours/Yearly (whichever comes first) Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb). Note: Do not use anti-seize compound on wheel hub. 1.
Removing the Clutch Shim 1. Shut off the engine, wait for all moving parts to stop, remove the key, engage the parking brake, and allow the machine to cool completely before starting these instructions. 2. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 70). g001297 Figure 68 1. Spring washers 3. Dust cap g010868 2. Lock nut Figure 70 3.
B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 72). Note: Do not discard the shim until proper clutch function has been confirmed. g010873 Figure 74 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 g010871 Figure 72 inch), then install the shim; refer to Troubleshooting (page 71). 1. Shim • If the gap is sufficient, proceed to the C. safety check in step F.
Cleaning the Engine-Cooling Fins and Shrouds Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Every 100 hours/Yearly (whichever comes first) 1. Disengage the blade-control switch (PTO) and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air-intake screen, the recoil starter, and the fan housing (Figure 76). 4.
Brake Maintenance Checking and Cleaning the Hydraulic-Unit Shrouds Adjusting the Parking Brake Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO) and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Move the seat forward. 4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 77). 5.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Check the belts for squealing when the belt is rotating; blades slipping when cutting grass; frayed belt edges; burn marks; and cracks, which are signs of a worn mower belt. Replace the mower belt if any of these conditions occur. Replacing the Mower Belt g026961 Figure 78 Left Side Shown 1. L-bracket 4. Rear linkage assembly 2. Linkage stop 5. Caliper 3. Gap 6. Wheel hub 9.
g027730 Figure 81 1. Position the belt cover 3. Ensure that the tab is under the metal catch 2. Slide the belt cover under the side catches g009038 Replacing the Hydraulic Pump-Drive Belt Figure 80 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler-grease fitting 3. Spring-loaded idler pulley 7. Belt guide 4. Ratchet 1. Disengage the blade-control switch (PTO) and engage the parking brake. 2.
Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator. 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.
4. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. Note: The switch is a part of the seat assembly. 5. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 6. Start the engine and run it at full throttle and disengage the brake. Note: The brake must be engaged and the motion-control levers must be out to start the engine.
Adjusting the Motion-Control Neutral-Lock Pivot the lever, allow the reverse-indicator springs to bring the levers back to neutral. Note: The wheels must stop turning or slightly creep in reverse. 11. Shut off the unit, remove the jumper wire from the wire harness, and plug the connector into the seat switch. 12. Remove the jack stands. 13. Raise the deck and install the height-of-cut pin. 1. Loosen the jam nut. 14. Check that the machine does not creep in neutral with the park brakes disengaged.
Hydraulic System Maintenance 7. Remove 1 dipstick from the hydraulic reservoir (Figure 88). 8. Wipe the dipstick off and thread the dipstick into the reservoir. Hydraulic System Safety 9. Remove the dipstick and look at the end (Figure 88). • Ensure that all hydraulic-fluid hoses and Important: Do not overfill the hydraulic lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. units with oil as damage may occur.
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 your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. • Use cardboard or paper to find hydraulic leaks.
Mower Deck Maintenance 7. Install the replacement hydraulic filter. 8. Install the pump-drive belt and the mower belt. 9. Remove the jack stands and lower the machine (Figure 89). 10. Add oil to the hydraulic reservoir and check for any leaks. Leveling the Mower Deck 11. Clean up any spilled oil. Setting up the Machine 12. Start the engine and let it run for about 2 minutes to purge air from the system. 13. Shut off the engine and check for leaks. 14.
g009196 Figure 92 1. 7.6 cm (3 inch) at position A is correct 2. 8.3 cm (3-1/4 inch) at position B is correct g027343 Figure 91 1. Deck-lift pedal 3. Transport lock 10. 2. Height-of-cut pin 6. Insert the height-adjustment pin into the 7.6 cm (3 inches) cutting-height location. 7. Release the transport lock and allow the deck to lower to the cutting height. 8. Raise the discharge chute. 9.
Note: Loosen or tighten the single-point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This regains some up and down adjustment on each of the 4 deck links. g009042 Figure 95 g027344 Figure 93 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4. Front deck adjustment 11. 1. Single-point adjustment bolt 13.
Servicing the Cutting Blades To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand. Blade Safety g006530 Figure 96 A worn or damaged blade can break, and a piece of the blade could be thrown toward you or bystanders, resulting in serious personal injury or death. Trying to repair a damaged blade may result in discontinued safety certification of the product. • Inspect the blades periodically for wear or damage.
Removing the Blades Checking for Bent Blades 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. Rotate the blades until the ends face forward and backward. 1. Hold the blade end using a rag or a thickly-padded glove. 4.
Note: If the blade stays in a horizontal position, the blade is balanced and can be used. Removing the Mower Deck Note: If the blade is not balanced, file some Lock out the spring-loaded deck arms before servicing or removing the mower deck. metal off the end of the sail area only (Figure 99). WARNING Deck-lift arm assemblies have stored energy. Removing the deck with out releasing the stored energy can cause serious injury or death. g000553 Figure 100 1. Blade 3. 2.
g009038 Figure 102 1. Clutch pulley 2. Mower belt 5. Square hole in the idler arm for the ratchet 6. Idler grease fitting 3. Spring-loaded idler pulley 7. Belt guide 4. Ratchet 7. Remove and retain the hardware on both sides of the deck as shown in Figure 103. g010252 Figure 103 1. Right stabilizer 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. 68 8. Raise the deck struts and secure them in the raised position. 9.
Replacing the Grass Deflector Cleaning Cleaning under the Mower WARNING Service Interval: Before each use or daily An uncovered discharge opening could allow the lawn mower to throw objects at you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the lawn mower unless you install a cover plate, mulch plate, grass deflector, or bagger. 1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 104). 1.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storing the Machine 1. Disengage the power takeoff (blade-control switch (PTO), engage the parking brake, and turn the ignition key to the OFF position. Remove the key. 2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system.
Troubleshooting Problem The malfunction-indicator light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Shut off the engine and let it cool. 2. There is old fuel in the fuel tank. 3. The fuel-shutoff valve is not open completely. 4. The air cleaner is dirty. 2. Use new fuel. 3. Open the fuel-shutoff valve. 5. The battery is not charged. 6. Incorrect fuel filters are being used or the fuel filters are dirty. 7.
Problem The engine loses power. The engine overheats. The mower pulls to the left or right (with levers fully forward) The machine does not drive. The machine vibrates abnormally. The machine produces an uneven cutting height. Possible Cause 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 the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6.
Problem The clutch does not engage. Possible Cause Corrective Action 1. The fuse is blown. 1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. 2. There is low voltage supply at the clutch. 2. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. 3. Replace the clutch. 4. Repair or replace the clutch lead wire or electrical system.
GND BK BK + - A C FUEL SENDER S B BU PK (PTO SWITCH) SW2 PK PK 2 3 BN BN BN V 4 5 BK BK U2 BK F4 PK 7 4 9 HOUR METER 7 W PK 12 OR 10 T SW6 (BRAKE) GND 15A 6 2 3 Y 11 LTGR SW4 (NEUT_L) BN 8 B PTO CLUTCH TVS DIODE BK A BN F3 SW5 (NEUT_R) PTO 1 PK FUEL_SOLENOID NEUTRAL 8 SEAT OR BRAKE 5 8 4 7 10A KEY_A 1 GN SW7 (SEAT) BN PK OR GY R OR R GY PK PK GY V SW1 (IGNITION) 2 5 1 3 B I S R 5 GN 2 OPTIONAL ACCESSORIES FUEL GROUND B+ KEY_S 74 MAGNETO
Notes:
The Toro Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Riding Product Conditions and Products Covered 3. If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at: The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the Toro Products listed below if defective in materials or workmanship.
