Form No. 3409-876 Rev B Z Master® Commercial 3000 Series Riding Mower with 60in TURBO FORCE® Side Discharge Mower Model No. 74958—Serial No. 400000000 and Up Register at www.Toro.com.
This spark ignition system complies with Canadian ICES-002 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. Please refer to the engine manufacturer’s information included with the machine.
Contents Servicing the Spark Plug................................... 45 Checking the Spark Arrester ............................. 46 Fuel System Maintenance ................................... 47 Servicing the Electronic Fuel-Injection System.......................................................... 47 Replacing the Low-Pressure Fuel Filter.............................................................. 47 Servicing the High-Pressure Fuel Filter............. 47 Servicing the Fuel Tank........................
Safety Schematics ............................................................. 78 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 fully 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 recommended hydro oil. 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.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery 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. Cutting/dismemberment of hand or foot—stay away from moving parts; keep all guards and shields in place. 1. Explosion hazard 6. Keep bystanders a safe distance away from the battery.
decal127-0326 127-0326 1. Read the Operator's Manual. decal126-4398 126-4398 1. Read the Operator’s Manual 2. Lock 3. Remove the key from the ignition and read the Operator's Manual before performing maintenance or servicing the machine. 2. Height-of-cut 3. Unlock decal125-9383 125-9383 1. Check hydraulic oil 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.
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: Ignition Switch Use this switch to start the mower engine. It has 3 positions: START , RUN, and OFF.
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 moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable. To adjust, 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. Important: Do not engage starter for more than 5 seconds at a time. If the engine fails to start, allow a 15 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor. Note: You may need multiple attempts to start the engine when you start it the first time after the fuel system has been without fuel completely.
Shutting Off the Engine Using the Motion-Control Levers CAUTION Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended. Always remove the ignition key and engage the parking brake when leaving the machine unattended, even if just for a few minutes. Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch to the OFF position. g004532 Figure 24 1. Motion-control lever—NEUTRAL-LOCK position 4. Backward 2.
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 20). 2.
Driving Backward Stopping the Machine 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 26). 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. Engage the parking brake when you leave the machine; refer to Engaging the Parking Brake (page 20).
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).
Adjusting the Height-of-Cut Pin 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. g008955 Figure 27 Transport-Lock Positions 1. Transport lock 3. UNLOCK position—does not lock the mower deck into transport position 2. LOCK position—mower deck locks into transport position 27 1. Move the transport lock to the lock position. 2.
g029955 Figure 29 1. Anti-scalp roller 4. Flange nut 2. Spacer 5. Bolt 3. Bushing g027343 Figure 28 1. Deck-lift pedal 3. Transport lock 2. Cut-of-height pin Adjusting the Anti-Scalp Rollers g029956 Figure 30 Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2.
Adjusting the Flow Baffle Cam Locks Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. This procedure is applicable only to machines with the flow-baffle locks. Certain models have nuts and bolts in place of the flow-baffle locks and can be adjusted the same. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.
Position B Use this position when bagging. Always align it with the blower opening. g005833 Figure 34 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.
After Operation After Operation Safety General Safety • Clean grass and debris from the cutting units, mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. • Shut off the fuel before storing or transporting the machine. • Disengage the drive to the attachment whenever g008948 you are transporting or not using the machine. Figure 36 • Use full-width ramps for loading the machine into 1. On position a trailer or truck. 2.
Note: This allows hydraulic fluid to bypass the pump enabling the wheels to turn. 3. Disengage the parking brake before pushing the machine. g027338 Figure 38 1. Traction unit tie-down loops g015123 Figure 37 1. Vertical to push the machine 4. 2. Horizontal to run the machine Rotate the release-valve levers horizontally to run the machine (Figure 37). Transporting the Machine Use a heavy-duty trailer or truck to transport the machine.
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 39). g028043 Figure 39 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 Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. • Check the torque on the wheel lug nuts. After the first 100 hours • 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.
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 genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty. Maintenance and Storage • Check the parking brake operation frequently.
Lubrication Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 lithium or molybdenum 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. Clean the grease fittings with a rag.
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 44 g006115 5. Figure 46 Remove the dust cap and adjust the caster pivots. 1. Seal guard Note: Keep the dust cap off until greasing is 2. Spacer nut with wrench flats done. 6. Remove the hex plug. 2. Raise the mower for access. 7. Thread a grease fitting into the hole. 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 47 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch g012997 Figure 48 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 48). 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 48).
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 48). Viscosity: See the table below.
Checking the Engine-Oil Level Service Interval: Before each use or daily Note: Check the oil when the engine is cold. WARNING g008804 Contact with hot surfaces may cause personal injury. Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Important: Do not overfill the crankcase with oil because damage to the engine may result. Do not run engine with oil below the Low mark because the engine may be damaged. 1.
Changing the Engine Oil 5. Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions). 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 52). Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so it drains better. 2. 3. 4.
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 43). 2.
Servicing the Spark Plug Service Interval: Every 200 hours—Check, clean and gap the spark plug. Make sure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench to remove and install the spark plug(s) and use 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. Checking the Spark Arrester Install the left hydraulic unit shroud (Figure 55). Checking the Spark Plug For Models with a Spark Arrester Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. Service Interval: Every 50 hours WARNING 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.
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 59 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 60). g000960 Figure 62 g032526 1. Positive battery post 3. Red (+) charger lead 2. Negative battery post 4. Black (-) charger lead Servicing the Fuses Figure 61 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 the 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 65 1. Engine block 7. 2.
7. If the machine 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 67). 8. Tighten the stop plate (Figure 67). g027340 Figure 67 Left control lever shown g008943 Figure 66 1. ROPS knob (locked position) 1. Control lever 3. Roll bar in the upright position 3. Stop plate 2. Bolt 4. Roll bar in the folded 2.
g001055 Figure 68 Checking the Wheel Lug Nuts Service Interval: After the first 8 hours g027341 Figure 69 Yearly 1. Slotted nut Check and torque the wheel lug nuts to 122 to 136 N∙m (90 to 100 ft-lb). Checking the Wheel-Hub Slotted Nut Service Interval: After the first 100 hours Every 500 hours 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.
Adjusting the Caster-Pivot Bearing Using the Clutch Shim Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, the shim can be removed to extend the clutch life. Service Interval: Every 500 hours/Yearly (whichever comes first) 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2.
Removing the Clutch Shim 1. 2. B. 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. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 74). Note: Do not discard the shim until proper clutch function has been confirmed. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 72).
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily g010873 Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 77). Figure 76 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Troubleshooting (page 75). • If the gap is sufficient, proceed to the safety check in step F. F. g008804 Perform the following safety check: i. Sit on the seat and start the engine. ii.
Checking and Cleaning the Hydraulic-Unit Shrouds 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 79). 5. Position the seat. g004218 Figure 78 1. Engine guard 4. Fan housing 2. Engine air-intake screen 5.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours 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. 1.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt. Replacing the Mower Belt 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2.
g027730 Figure 83 g009039 1. Position the belt cover. 3. Ensure that the tab is under the metal catch. Figure 84 2. Slide the belt cover under the side catches. 1. Idler pulley 5. Left hydraulic-pump pulley 2. Clutch pulley 6. Square hole in the idler arm 7. Idler spring 3. Pump-drive belt 4. Right hydraulic-pump pulley Replacing the Hydraulic Pump-Drive Belt 5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 84). 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.
4. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. the lever, allow the reverse-indicator springs to bring the levers back to neutral. Note: The switch is a part of the seat assembly. creep in reverse. Note: The wheels must stop turning or slightly 5. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 11.
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 89 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 90). 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 59) and Replacing the Hydraulic Pump-Drive Belt (page 60). 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 92). g008968 Figure 92 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 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 tires.
g009196 Figure 94 1. 7.6 cm (3 inches) at position A is correct. 3. Measure here from the blade tip to hard surface. 2. 8.3 cm (3-1/4 inches) at position B is correct. 4. Measure at position A and B on both sides. 10. g027345 Figure 96 1. Bolts at the bottom of the height-of-cut plate 12. 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 a 7.6 mm (3 inches) height (Figure 95).
15. 16. On both sides of the deck, measure from the level surface to the back tip of the blade (postion B) as shown in Figure 94. Servicing the Cutting Blades Note: The measurement should read 8.3 cm (3-1/4 inches) 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. Fine-tune the screw adjuster by turning it to get 8.3 mm (3-1/4 inches) height (Figure 95).
Inspecting the Blades Checking for Bent Blades 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 engage the parking brake. 1. Inspect the cutting edges (Figure 98). 2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to Sharpening the Blades (page 70). 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Removing the Blades WARNING Blades must be replaced if a solid object is hit, if the blade is out of balance, or if the blade is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in nonconformance with safety standards. A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.
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 Before servicing or removing the mower deck, lock out the spring-loaded deck arms. metal off the end of the sail area only (Figure 102). WARNING Deck-lift-arm assemblies have stored energy. Removing the deck without releasing the stored energy can cause serious injury or death. g000553 Figure 102 1. Blade 3.
8. Raise the deck struts and secure them in the up position. 9. Slide the deck out to the right side of the machine. Replacing the Grass Deflector WARNING 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. Do not operate the lawn mower unless you install a cover plate, a mulch plate, grass deflector or bagger. g009038 Figure 104 1. Clutch pulley 2. Mower belt 5.
6. Cleaning Place the J-hook end of the spring around the grass deflector (Figure 106). Important: The grass deflector must be able Cleaning under the Mower to rotate. Lift the deflector up to the full open position and ensure that it rotates into the full down position. 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 engage the parking brake. 2.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storage 1. 2. Disengage the blade-control switch (PTO), engage the parking brake, turn the ignition key to the OFF position, and remove the key. Remove grass clippings, dirt, and grime from the external parts of the entire machine (especially the engine and hydraulic system). Clean dirt and chaff from the outside of the engine-cylinder-head fins and the blower housing. B.
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 Electrical Schematic
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.
