Form No. 3411-990 Rev B Z Master® Professional 5000 Series Riding Mower with 60in or 72in TURBO FORCE® Rear Discharge Mower Model No. 74943—Serial No. 400000000 and Up Model No. 74945—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 Fuel System Maintenance ................................... 45 Servicing the Electronic Fuel-Injection System.......................................................... 45 Replacing the Low-Pressure Fuel Filter.............................................................. 45 Servicing the High-Pressure Fuel Filter............. 45 Servicing the Fuel Tank..................................... 45 Electrical System Maintenance ........................... 46 Electrical System Safety .....................
Safety 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. • Read and understand the contents of this Operator’s Manual before you start the engine.
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. decal99-8936 99-8936 1. Machine speed 4. Neutral 2. Fast 3. Slow 5. Reverse 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 fully raised and locked position and wear the seat belt.
decal116-1716 116-1716 decal109-6036 109-6036 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 1. Read the Operator’s Manual. 9. Neutral 10. Operator-presence switch 2. Remove the ignition key and read the instructions before servicing or performing maintenance. 3. Height of cut decal112-9028 112-9028 decal116-4858 1. Warning—stay away from moving parts; keep all guards in place. 116-4858 decal114-4466 114-4466 1. Main (25 A) 3. Charge (25 A) 2.
decaloemmarkt Manufacturer's Mark 1. Indicates the blade is identified as a part from the original machine manufacturer. decal116-5988 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged decal117-0346 117-0346 1. Fuel leak hazard—read the Operator's Manual; do not attempt to remove the roll bar; do not weld, drill, or modify the roll bar in any way. decal116-8726 116-8726 1. Read the Operator’s Manual for recommended hydraulic fluid. decal117-3848 117-3848 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. decal117-3864 117-3864 1. Read the Operator’s Manual. 2. Fill to bottom of filler neck; warning—do not overfill the tank. decal121-7586 121–7586 1. Fast 2. Variable speed control 3. Slow 4. Power takeoff (PTO) decal126-4398 126-4398 1.
decal131-4036 131-4036 1. Maximum drawbar pull 36 kg (80 lb) 2. Read the Operator's Manual. decal127-6663 127-6663 1. Warning—read the Operator's Manual. 2. Crushing hazard—1) Engage the parking brake, shut off the engine, and remove the key from the ignition; 2) Jack the machine using a manufacturer-approved jack, and always use a jackstand. decal125-9383 125–9383 1. Check the hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2.
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.
Product Overview g013112 Figure 5 1. PTO Switch 4. Hour meter/Safety-interlock display/Fuel gauge 2. Throttle control 5. Ignition switch 3. Malfunction indicator light (MIL) 6. Fuses g027405 Figure 4 1. Height-of-cut deck-lift pedal 6. Roll bar 2. Transport lock 7. Seat belt 3. Parking-brake lever 8. Fuel cap 4. Controls 5. Motion-control levers Hour Meter The hour meter records the number of hours the engine has operated. It operates when the engine is running.
Electronic-Control Unit Malfunction-Indicator Light The electronic-control unit (ECU) continuously monitors the operation of the EFI system. If a problem or fault within the system is detected, the malfunction-indicator light (MIL) illuminates. The MIL is the red light located in the right console panel. Once the MIL illuminates, make initial troubleshooting checks; refer to the MIL section under Troubleshooting (page 73). g008950 Figure 6 1. Fuel gauge (bars) 4. Safety-interlock symbols 2.
Model Weight 60 inch Mower Decks 577 kg (1,271 lb) 72 inch Mower Decks 606 kg (1,335 lb) 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.
Using Stabilizer/Conditioner containers on the ground, away from your vehicle before filling. • Remove the equipment from the truck or trailer 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.
Checking the Engine-Oil Level Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level (page 16). Breaking in a New Machine New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance.
1. To lower the roll bar, apply forward pressure to the upper part of the roll bar. Think Safety First 2. Pull both knobs out and rotate them 90° so they are not engaged (Figure 8). 3. Lower the roll bar to the down position (Figure 8). Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Operating the machine on wet grass or steep slopes can cause sliding and loss of control.
CAUTION This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Wear hearing protection when operating this machine. Use protective equipment for your eyes, ears, hands, feet, and head. g000963 Figure 9 1. Safe Zone—use the machine here on slopes less than 15 degrees or flat areas. 2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15 degrees and near drop-offs or water. 3.
position, and move the motion-control levers to the NEUTRAL-LOCK position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should shut off. Repeat for other motion control. The safety-interlock system also is designed to shut off the engine when the traction controls are moved from the locked position with the parking brake engaged or if you rise from the seat when the PTO is engaged.
Changing the Seat Suspension • Keep your hands and feet away from the cutting • The seat adjusts to provide a smooth and comfortable ride. Position the seat where you are most comfortable. • To adjust, turn the knob in front either direction to provide the best comfort (Figure 14). • • • • • g019768 Figure 14 1.
Disengaging the Parking Brake • Keep the roll bar in safe operating condition by thoroughly inspecting it periodically for damage and keeping all the mounting fasteners tight. • Replace a damaged roll bar. Do not repair or alter it. Slope Safety • Slow down the machine and use extra care on hillsides. Travel up and down on hillsides. Turf conditions can affect the stability of the machine. • Avoid turning the machine on slopes.
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.
Starting and Shutting Off the Engine Note: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely. Starting the Engine 1. 2. 3. 4. 5. Raise the roll bar up and lock it into place, sit on the seat, and fasten the seat belt. Move the motion controls to the NEUTRAL-LOCK position. Engage the parking brake; refer to Engaging the Parking Brake (page 21). Move the blade-control switch (PTO) to the OFF position (Figure 21).
Using the Motion-Control Levers g027337 Figure 23 g004532 Figure 24 Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine, as fuel leakage may occur. Engage the parking brake before transporting. Make sure that you remove the key as the fuel pump may run and cause the battery to lose charge. 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2. Center, unlocked position 5. Front of machine 3.
Driving Forward CAUTION Note: The engine stops when you move the traction-control with the parking brake engaged. Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine. To stop, pull the motion-control levers to the NEUTRAL position. • Use caution when making turns. • Slow the machine down before making sharp turns. 1. Disengage the parking brake; refer to Disengaging the Parking Brake (page 21). 2.
Adjusting the Height of Cut 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 27). g008953 Figure 26 Stopping the Machine 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.
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 28. 3.
g024244 Figure 31 1. Carriage bolt 3. Nut 2. Skid g024243 Figure 30 1. Bolt 3. Anti-scalp roller 2. Bushing 4. Flange nut 4. Move each skid to the desired position and secure them with the carriage bolts and nuts. Note: Only use the top or center sets of holes to adjust the skids. The bottom holes are used when switching sides on the mower deck, at which time they become the top holes on the other side of the mower.
grass is sparse, or it is late fall when grass grows more slowly. After Operation Alternating the Mowing Direction After Operation Safety Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization. General Safety • Clean grass and debris from the cutting units, Mowing at Correct Intervals • Grass grows at different rates at different times of the year.
Using the Drive-Wheel-Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel-release valves. g024246 Figure 33 1. Vertical to push the machine WARNING The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns. 4.
WARNING Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Ensure that the roll bar is in the up position and use the seat belt when loading or unloading the machine. Ensure that the roll bar will clear the top of an enclosed trailer. • Use only a full-width ramp; do not use individual ramps for each side of the machine.
g027996 Figure 36 1. Full-width ramp in stowed position 4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground 2. Side view of full-width ramp in loading position 5. H=height of the trailer or truck bed to the ground 3. Not greater than 15 degrees 6.
Maintenance 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. Before each use or daily • • • • • • • • Check the safety system. Check the engine-oil level.
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 perform any maintenance. Pre-Maintenance Procedures by a safety device. Check their proper operation regularly.
Lubrication Yearly—Grease the mower-deck idler arms. Important: Make sure cutting unit spindles are Grease more frequently when operating conditions are extremely dusty or sandy. full of grease weekly. 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. 1.
Lubricating the Caster-Wheel Hubs 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 40 g006115 6. Figure 42 Remove the dust cap and adjust the caster pivots, and keep the dust cap off until greasing is done; refer to Adjusting the Caster-Pivot Bearing (page 51). 1. Seal guard 7. Remove the hex plug and thread a grease fitting into the hole. 2. Raise the mower for access. 8.
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 43 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch g012997 Figure 44 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 44). 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 44).
Servicing the Engine Oil Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Oil Type: Detergent oil (API service class SJ or higher) Important: Do not press on the soft, inside area of the filter. 4. Oil Capacity: with a filter change, 1.7 L (58 oz); with no filter change, 1.4 L (48 oz) Install the air-cleaner cover and secure the latches (Figure 44). 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. g024213 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. g027659 Figure 46 40 2. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely. 3.
5. 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). g024213 g027660 Figure 48 g027734 Figure 47 41 6. Start the engine and drive to a flat area. 7. Check the oil level again.
Changing the Engine-Oil Filter Servicing the Engine-Oil Cooler Service Interval: Every 200 hours Service Interval: Every 200 hours Note: Change the engine-oil filter more frequently 1. when operating conditions are extremely dusty or sandy. Remove the bolts holding the oil cooler to the engine housing . 2. Clean the inside of the oil cooler with a brush. 3. Install the oil cooler to the engine housing. 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 40). 2.
Servicing the Spark Plug Service Interval: Every 200 hours—Check, clean and regap the spark plug. Make sure 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. g024214 Type : Champion® XC12YC, Champion® Platinum3071 or equivalent Air Gap: 0.76 mm (0.030 inch) Removing the Spark Plug 1.
Checking the Spark Plug Checking the Spark Arrester Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. For Models with a Spark Arrester 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. Service Interval: Every 50 hours Set the gap to 0.76 mm (0.030 inch).
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 55 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 57). g000960 Figure 58 g032526 1. Positive battery post 3. Red (+) charger lead 2. Negative battery post 4. Black (-) charger lead Servicing the Fuses Figure 57 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 g024213 Service Interval: Before each use or daily Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged. Checking the Rollover Protection System (ROPS) Knobs g013117 Service Interval: Before each use or daily Figure 61 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.
7. If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight (Figure 63). 8. Tighten the stop plate (Figure 63). g027407 Figure 63 Left control lever shown g008943 Figure 62 1. ROPS knob (locked position) 1. Control lever 3. Roll bar in the upright position 4. Roll bar in the folded 2.
g001055 Figure 64 Checking the Wheel-Lug Nuts Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb). g027408 Figure 65 Checking the Wheel-Hub Slotted Nut 1. Slotted nut Service Interval: After the first 100 hours Adjusting the Caster-Pivot Bearing Every 500 hours Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb). Service Interval: Every 500 hours/Yearly (whichever comes first) 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 68). g001297 Figure 66 1. Spring washers 3. Dust cap g010868 2. Lock nut Figure 68 3.
B. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 70). Note: Do not discard the shim until proper clutch function has been confirmed. g010873 Figure 72 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 g010871 Figure 70 inch), then install the shim; refer to Troubleshooting (page 73). 1. Shim • If the gap is sufficient, proceed to the C. safety check in step F.
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 73). g024213 g004218 Figure 74 1. Engine guard 4. Fan housing 2. Engine air-intake screen 5. Screw 3. Bolt g009191 Figure 73 Checking and Cleaning the Hydraulic-Unit Shrouds Before each use, remove any buildup of grass, dirt, or other debris from the engine screen.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours g024214 Every 500 hours thereafter Note: This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 1. Drive the machine onto a level surface. 2. Disengage the blade-control switch (PTO), move the motion control levers to the NEUTRAL-LOCK position, and engage the parking brake. 3. Shut off the engine, wait for all moving parts to stop, and remove the key.
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 Counter-Rotating Belt g026961 Figure 76 Left Side Shown 1. L-bracket 4. Rear linkage assembly 2. Linkage stop 5. Caliper 3. Gap 6. Wheel hub 9. Disengage the parking brake, the lever should be in the down position. 10.
7. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 77). 8. Remove the belt from the mower deck pulley (Figure 77). 9. Remove the belt from the remaining pulleys (Figure 77). 10. Using the ratchet in the square hole, install the new belt around the mower pulleys and the idler pulleys (Figure 77).
g027730 Figure 80 g009039 Figure 81 Replacing the Hydraulic Pump-Drive Belt 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 mower belt; refer to Replacing the Mower Belt (page 57). 4. Raise the machine and support it with jack stands (Figure 81). 1. Idler pulley 5. Left hydraulic-pump pulley 2. Clutch pulley 6.
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.
Note: The switch is a part of the seat assembly. 4. 5. 6. Note: The wheels must stop turning or slightly creep in reverse. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 11. Shut off the machine. 12. Remove the jumper wire from wire harness and plug the connector into seat switch. Note: Engage the parking brake and move 13. Remove the jack stands. the motion-control levers out before starting the engine.
Adjusting the Motion Control Neutral-Lock Pivot Hydraulic System Maintenance The flanged nut can be adjusted to obtain a more desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 86 for adjustment options. Hydraulic System Safety 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel.
8. Wipe the dipstick off and thread the dipstick into the reservoir. 9. Remove the dipstick and look at the end (Figure 87). 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. Important: Do not overfill the hydraulic units with oil as damage may occur.
g008970 1. Jack stands Remove both the mower belt and the pump-drive belt; refer to Replacing the Mower Belt (page 57) and Replacing the Hydraulic Pump-Drive Belt (page 58). Note: This prevents oil from getting on the belts. 5. Place a drain pan under the filter, remove the old filter, and wipe the surface clean (Figure 89). g008968 Figure 89 Bottom view of the machine 1. Filter locations 6. Install the replacement hydraulic filter. 8. Install the pump-drive belt and the mower belt. 9.
Mower Deck Maintenance Leveling the Mower Deck Setting up the Machine Note: Ensure that the mower deck is level before matching the height of cut (HOC). 1. Position the mower on a flat surface. 2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, 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. Check tire pressure of the drive tires. 5.
g024245 Figure 91 1. 7.6 cm (3 inches) at position A is correct. 2. 8.3 cm (3-1/4 inches) at position B is correct. 9. g027410 3. Measure here from the blade tip to the hard surface. 4. Measure at position A and B on both sides. Figure 92 1. Whizlock nut 2. Adjuster screw 10. If needed, loosen the whizlock nut on the side of the yoke and the jam nut on top. Fine-tune the screw adjuster by turning it to get 7.6 cm (3 inches) height (see Figure 92). 3. Jam nut 4.
13. Torque the 2 bolts to 37 to 45 N∙m (27 to 33 ft-lb). 14. On both sides of the deck, measure from the level surface to the back tip of the blade (position B). Ensure the measurement is 8.3 cm (3-1/4 inches) (Figure 91). 15. Fine-tune the screw adjuster by turning it to get 8.3 mm (3-1/4 inches) height (Figure 92). To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise. 16.
4. If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade (Figure 96). 6. Measure from a level surface to the cutting edge of the blades at the same position as in step 4. Note: The difference between the dimensions obtained in steps 4 and 5 must not exceed 3 mm (1/8 inch). Note: If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced.
Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 100). Note: Maintain the original angle. Note: The blade retains its balance if the same amount of material is removed from both cutting edges. g000276 Figure 100 g004536 Figure 98 Left and Center Spindle Shown 1. Sail area of the blade 2. Blade 1. Sharpen at original angle. 2. 3. Curved washer 4. Blade bolt Check the balance of the blade by putting it on a blade balancer (Figure 101).
2. Install the right blade, curved washer, and blade bolt (left-hand threaded bolt) to the spindle shaft (Figure 102 and Figure 103). g004536 Figure 102 Left and center spindle shown g024248 1. Sail area of the blade 2. Blade 3. Figure 103 3. Curved washer 4. Blade bolt 1. Front of mower deck 4. Counter-rotating blade 2. Right-hand threaded blade 5. Left-hand threaded blade bolts bolt 3. Regular blades Torque the blade bolts to 115 to 150 N∙m (85 to 110 ft-lb); refer to Figure 103.
Note: This locks the deck-lift arms in the lowest position when the deck is removed and the stored energy in the deck spring is released. 4. Remove the belt covers. 5. Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 104). 6. Rotate the mower deck idler clockwise, lift up on the belt-guide tab, and remove the mower-deck belt from the clutch (Figure 104). g024220 Figure 105 1. Right stabilizer 2. Deck strut (right side shown) 3.
Cleaning Cleaning under the Mower Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set 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 to the transport position. Disposing of Waste Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Cleaning and Storage C. Shut off the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 45). D. Start the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. 1. 2. Disengage the blade-control switch (PTO), engage the parking brake, turn the ignition key to the OFF position, and remove the key.
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 a faulty valve in the fuel tank. 3. The air cleaner is dirty. 2. Contact an Authorized Service Dealer. 3. Make sure that the air cleaner and precleaner are clean. Replace if necessary. 4. Charge or replace the battery. 5. Contact an Authorized Service Dealer. 4. The battery is not charged. 5.
Problem 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 tracking needs adjustment 1. Adjust the tracking. 2. The tire pressure in the drive tires is not correct. 2. Adjust the tire pressure in the drive tires. 1. The bypass valves are not closed tight. 1. Tighten the bypass valves. 2. The pump belt is worn, loose, or broken. 3.
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 75 MAGNETO
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.
