Form No. 3424-609 Rev A Z Master® Commercial 3000 Series Riding Mower with 48in, 52in, 60in, or 72in TURBO FORCE® Side Discharge Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 74949—Serial No. 74950—Serial No. 74952—Serial No. 74959—Serial No. 75932—Serial No. 75936—Serial No. 78953—Serial No.
Introduction 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. This rotary-blade, riding lawn mower is intended to be used by professional, hired operators.
Contents (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Safety ....................................................................... 4 General Safety ................................................... 4 Slope Indicator ................................................... 5 Safety and Instructional Decals .......................... 6 Product Overview ................................................... 13 Controls ...............
Safety Servicing a Kohler® Engine............................... 45 Checking the Spark Arrester ............................. 51 Fuel System Maintenance ................................... 51 Replacing the Fuel Filter ................................... 51 Servicing the Fuel Tank..................................... 51 Electrical System Maintenance ........................... 52 Electrical System Safety ................................... 52 Servicing the Battery.........................................
Slope Indicator g011841 Figure 3 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. decal93-7818 93-7818 decalbatterysymbols 1. Warning—read the Operator's Manual for instructions on torquing the blade bolt/nut to 115 to 149 N∙m (85 to 110 ft-lb). Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery. 2.
decal106-5517 106-5517 1. Warning—do not touch the hot surface. 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. decal114-4466 114-4466 1. Main (25 A) 3. Charge (25 A) 2. PTO (10 A) 4. Auxiliary (15 A) decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is down. 2.
decal116-5988 116-5988 1. Parking brake—engaged decal117-3848 117-3848 2. Parking brake—disengaged 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. Cutting/dismemberment of hand or foot—stay away from moving parts; keep all guards and shields in place. decal116-8726 116-8726 1.
decal126-2055 126-2055 1. Wheel lug nut torque 95 ft-lb (129 N∙m) (4x) 2. Wheel hub nut torque 235 ft-lb (319 N∙m) 3. Read and understand the Operator’s Manual before performing any maintenance, check torque after first 100 hours then every 500 hours thereafter. decal126-4659 126-4659 1. Warning—hot pulley; allow to cool. decal133-8062 133-8062 decal121-7551 121-7551 9 1. Power takeoff (PTO) 4. Continuous-variable setting 2. Choke 3. Fast 5.
decal132-5063 decal126-4398 132-5063 Machines with MyRide™ Only 126-4398 3. Unlock 1. Read the Operator’s Manual. 2. Lock 1. Cam lock 2. Cam unlock 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. decal136-5508 136-5508 2. Height-of-cut 1. Belt routing decal131-4036 131-4036 1. Maximum drawbar pull 36 kg (80 lb) 2. Read the Operator's Manual.
decal125-9383 125-9383 1. Check the hydraulic fluid every 50 operating hours. 3. Check the tire pressure every 50 operating hours. 2. Read the Operator’s Manual for information on lubricating the machine. 4. Read the Operator’s Manual before servicing or performing maintenance.
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.
Control Panel Product Overview g008951 Figure 5 1. Blade-control switch (power takeoff) 4. Hour meter/Safety-interlock display 2. Choke control 5. Ignition switch 3. Throttle control 6. Fuses g029631 Figure 4 1. Side-discharge deflector 8. Rear-shock assembly (machines with MyRide™ only) 2. Height-of-cut deck lift pedal 9. Seat belt 3. Parking-brake lever 10. Fuel cap 4. Transport lock 11. Mower deck 5. Controls 6. Motion-control levers 12. Caster wheel 13.
Fuel-Shutoff Valve Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 32). Attachments/Accessories A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Exmark.com for a list of all approved attachments and accessories. g008950 Figure 6 1. Fuel gauge (bars) 4.
Specifications Note: Specifications and design are subject to change without notice.
Operation • Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner. Always place containers on the ground, away from your vehicle before filling. Note: Determine the left and right sides of the machine from the normal operating position. • 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.
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
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.
Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily WARNING Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately. If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. 1.
Machines without MyRide™ Suspension System 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 (Figure 10). To unlatch the seat, push the seat latch forward (Figure 12). g008956 Figure 12 g019754 Figure 10 1. Seat latch Unlatching the Seat 2.
Adjusting the MyRide™ Suspension System Adjust the rear-shock assemblies (Figure 15). 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. g030024 Adjusting the Rear-Shock Assemblies The slots for the rear-shock assemblies have detent positions for reference.
During Operation • Never run an engine in an area where exhaust During Operation Safety • • General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Wear appropriate clothing, including eye protection; long pants; slip-resistant, substantial footwear; and hearing protection. Tie back long hair and do not wear loose jewelry. Use your full attention while operating the machine.
injury or death. The operator is responsible for safe slope operation. Operating the machine on any slope requires extra caution. Before using the machine on a slope, do the following: – Review and understand the slope instructions in the manual and on the machine. – Use an angle indicator to determine the approximate slope angle of the area. – Never operate on slopes greater than 15 degrees. – Evaluate the site conditions of the day to determine if the slope is safe for machine operation.
Operating the Parking Brake Operating the Mower Blade-Control Switch (PTO) Always engage the parking brake when you stop the machine or leave it unattended. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Parking Brake Engaging the Blade-Control Switch (PTO) Park the machine on a level surface. Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Operating the Choke Starting the Engine Use the choke to start a cold 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. 1. Pull up the choke knob to engage the choke before using the key switch (Figure 24). 2. Push down the choke knob to disengage the choke after the engine has started (Figure 24).
Using the Motion-Control Levers Shutting Off the Engine CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the key and engage the parking brake when leaving the machine unattended. g004532 Figure 27 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 Backward WARNING The machine can spin very rapidly. You may lose control of the machine and cause personal injury or damage to the machine. 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 29). • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged.
Using the Side Discharge Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Using the Transport Lock The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position of the mower deck (Figure 30).
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 31. 3.
g027727 g029957 Figure 35 Figure 34 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 Operating Tips Use this position when bagging. Always align it with the blower opening. 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. Always try to have 1 side of the mower deck free from uncut grass, which allows air to be drawn into the mower deck.
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. Keeping the Underside of the Mower Deck Clean Clean clippings and dirt from the underside of the mower deck after each use. If grass and dirt build up inside the mower deck, cutting quality will eventually become unsatisfactory.
2. 3. Transporting the Machine Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 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.
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 41). 4. Back the machine up the ramp (Figure 42). g028043 Figure 42 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. 5. Shut off the engine, remove the key, and engage the parking brake. 6.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 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. For Kawasaki engines—check the engine-oil level.
Maintenance Service Interval Every 500 hours Monthly Yearly Yearly or before storage Maintenance Procedure • For Kawasaki engines—replace the safety air filter. (more often in dusty or sandy conditions). • For Kohler engines—replace the air-cleaner paper element (more often under dusty, dirty conditions). • For Kohler engines—replace the spark plug(s). • For Kawasaki engines—Replace the fuel filter (more often in dusty, dirty conditions). • Check the wheel lug-nut torque.
Lubrication Greasing the Mower Deck Service Interval: Yearly—Grease the pump-belt-idler arm. Yearly—Grease the front caster pivots (more often in dirty or dusty conditions). Yearly—Repack the front caster-wheel bearings (more often in dirty or dusty conditions). Greasing the Machine Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 lithium or molybdenum grease 1.
5. Note: Keep the dust cap off until greasing is Lubricating the Caster-Wheel Hubs done. Service Interval: Yearly Remove the dust cap and adjust the caster pivots. 6. Remove the hex plug. 7. Thread a grease fitting into the hole. 8. Pump grease into the fitting until it oozes out around the top bearing. 9. Remove the grease fitting in the hole. 10. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
12. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing. 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. 14. Insert the second bearing and new seal into the wheel. 15. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. 16.
Engine Maintenance Identifying the Engine Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 49). g230252 Figure 49 1. Kawasaki engine 2. Kohler engine • For Kawasaki engine maintenance, refer to Servicing a Kawasaki® Engine (page 40). • For Kohler engine maintenance, refer to Servicing a Kohler® Engine (page 45). Servicing a Kawasaki® Engine Engine Safety • Shut off the engine before checking the oil or adding oil to the crankcase.
Servicing the Air Cleaner Important: Do not attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged. Replace both filters. Service Interval: Every 250 hours—For Kawasaki engines—replace the primary air filter (more often in dusty or sandy conditions). 7. Every 250 hours—For Kawasaki engines—check the safety air filter. (more often in dusty or sandy conditions).
Servicing the Engine Oil 3. Engine-Oil Specifications To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 53). Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Crankcase Capacity: • Model 74949, 74950, 75932, 75936—2.3 L (78 fl oz) with a filter change; 2.1 L (71 fl oz) without a filter change g008804 • Model 74952, 78953—2.1 L (71 fl oz) with a filter change; 1.
2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 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 54). 6.
Changing the Engine-Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). Service Interval: Every 100 hours 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 42). 2. Change the engine-oil filter (Figure 56). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
Checking the Spark Plug Servicing a Kohler® Engine Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 60, you have a Kohler engine. Important: Refer to your engine owner’s manual If you see light brown or gray on the insulator, the engine is operating properly.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Release the latches on the air cleaner and pull the air-inlet cover off the air-cleaner body (Figure 61). 4. Clean the air-inlet screen and cover. 5. Install the air-inlet cover and secure it with the latches (Figure 61). g012997 Figure 62 1. Inner filter 2. Primary filter 4. Latch 5. Air-cleaner body 3. Air-cleaner cover 10. g012996 Figure 61 1. Air-inlet cover 3.
Installing the Filters 2. Important: To prevent engine damage, always operate the engine with both air filters and the cover installed. 1. If you are installing new filters, check each filter for shipping damage. Note: Ensure that the engine is cool so that the oil has had time to drain into the sump. 3. Note: Do not use a damaged filter. 2. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Changing the Engine Oil Service Interval: Every 100 hours (more often in dirty or dusty conditions). Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. g008804 Note: This warms the oil so that it drains better. 2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely. 3. Disengage the blade-control switch (PTO) and engage the parking brake. 4.
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 64). g008804 g027660 Figure 66 7. Start the engine and drive to a flat area. 8. Check the oil level again. g027477 Figure 67 Changing the Engine-Oil Filter Service Interval: Every 200 hours—For Kohler engines—change the engine-oil filter (more often in dirty or dusty conditions). 1.
Servicing the Spark Plug Service Interval: Every 200 hours—For Kohler engines—check the spark plug(s). Every 500 hours—For Kohler engines—replace the spark plug(s). Type: Champion XC12YC g206628 Air Gap: 0.76 mm (0.03 inch) Figure 69 Removing the Spark Plug 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.
Checking the Spark Arrester Fuel System Maintenance For Machines with a Spark Arrester Replacing the Fuel Filter Service Interval: Every 50 hours Service Interval: Every 200 hours (more often in dusty, dirty conditions). WARNING Every 500 hours/Yearly (whichever comes first) (more often in dusty, dirty conditions). Hot exhaust-system components may ignite fuel vapors even after you shut off the engine.
Electrical System Maintenance 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 72. 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.
Installing the Battery Charging the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 72). WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from the battery. Important: Always keep the battery fully charged (1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). 1.
Servicing the Fuses Drive System Maintenance 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. Checking the Seat Belt The fuses are located on the console to the right of the seat (Figure 75). 1. To replace the fuses, pull out on the fuse to remove it. 2. Install a new fuse (Figure 75).
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open flat area, move the motion-control levers to the NEUTRAL-LOCK position. 3. Move the throttle midway between fast and slow. 4. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks. • If it tracks to the right, loosen the bolts and adjust the left stop plate rearward on the left T-slot until the machine tracks straight (Figure 78).
Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) Maintain the air pressure in the front and rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold to get the most accurate pressure reading. g001055 Figure 79 g024121 Figure 80 1. Slotted nut Checking the Wheel-Lug Nuts Adjusting the Caster-Pivot Bearing Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb).
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 83). g001297 g010868 Figure 81 1. Spring washers Figure 83 3. Dust cap 2. Locknut 4. Check the condition of the wire-harness leads, connectors, and terminals. Note: Clean or repair as necessary.
Note: Do not discard the shim until the clutch is functioning properly. g010873 Figure 87 1. Feeler gauge g010871 Figure 85 1. Shim C. • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Using the Clutch Shim (page 57). Using a pneumatic line, blow out any debris from under the brake pole and around the brake spacers. D. Torque each bolt (M6 x 1) to 12.3 to 13.7 N∙m (9.5 to 10.5 ft-lb). E. Using a 0.25 mm (0.
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. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the air-intake screen, the recoil starter, and the fan housing (Figure 89). 4.
Brake Maintenance Checking and Cleaning the Hydraulic-Unit Shrouds Adjusting the Parking Brake Service Interval: Before each use or daily 1. 2. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. Service Interval: After the first 100 hours Every 500 hours thereafter 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.
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 g026961 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
g027730 Figure 94 Replacing the Hydraulic Pump-Drive Belt g009038 Figure 93 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 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.
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. 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 bolts and flange nuts installed in the levers (Figure 96). 4.
4. Lower deck to the ground. 5. Raise the rear of machine up and support it with jack stands (or equivalent support). Note: Raise the machine just high enough to allow the drive wheels to turn freely. 6. 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. 7. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 8.
g008620 Figure 99 Right Motion Control Shown 1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing. 2. Most resistance (firmest feel) 3. Damper 4. Medium resistance (medium feel) g010187 5. Least resistance (softest feel) Figure 98 1. Double nuts 12.
Hydraulic System Maintenance Hydraulic System Safety 6. Remove 1 dipstick from the hydraulic reservoir (Figure 101). 7. Wipe the dipstick off and thread the dipstick into the reservoir. 8. Remove the dipstick and look at the end (Figure 101). • Seek immediate medical attention if fluid is injected Important: Do not overfill the hydraulic into skin. Injected fluid must be surgically removed within a few hours by a doctor. units with fluid, as damage may occur.
Replacing the Hydraulic Fluid and Filters Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid. Every 250 hours—Change the hydraulic filters and hydraulic fluid when using Mobil® 1 fluid (more often in dirty or dusty conditions). Every 500 hours—Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions).
Mower Deck Maintenance 9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A) as shown in Figure 105. Note: The measurement should read 7.6 mm (3 inches) Leveling the Mower Deck Leveling the Deck 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
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. g017036 Figure 108 g027344 Figure 106 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 109 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 Note: If the blade is not balanced, file some metal off the end of the sail area only (Figure 112). Replace the blades if they hit a solid object, or if the blade is out of balance or bent. 1. Hold the blade end using a rag or thickly padded glove. 2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 111). g000553 Figure 113 1. Blade 3. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1.
4. Remove the belt covers. 5. Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 114). 6. Rotate the deck idler clockwise and remove the mower belt (Figure 114). g010252 Figure 115 1. Right stabilizer 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. 8. Raise the deck struts and secure them in the raised position. 9. Slide the deck out to the right side of the machine.
Cleaning Cleaning under the Mower Deck Service Interval: Before each use or daily 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Raise the mower deck to the TRANSPORT position. g015594 Figure 116 1. Bolt 5. Spring installed 2. Spacer 6. Grass deflector 3. Locknut 7.
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 starter does not crank. The engine does not start, starts hard, or fails to keep running. Possible Cause 1. The blade-control switch is engaged. 1. Disengage the blade-control switch. 2. The parking brake is disengaged. 3. The motion-control levers are not in the NEUTRAL-LOCK position. 4. You are not sitting in the operator’s seat. 5. The battery is dead. 6. The electrical connections are corroded or loose. 7. A fuse is blown. 8. A relay or switch is damaged. 2.
Problem The machine pulls to the left or right (with levers fully forward) The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. 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. The pump belt is off a pulley. 4.
Schematics g009180 Electrical Schematic—Kawasaki Engines (Rev.
g020788 Electrical Schematic—Kohler Engines (Rev.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
