Form No. 3400-705 Rev C Z Master® Professional 5000 Series Riding Mower with 60in TURBO FORCE® Side Discharge Mower Model No. 74991—Serial No. 316000001 and Up Register at www.Toro.com.
You may contact Toro directly at www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Contents Servicing the High-Pressure Fuel Filter............. 46 Servicing the Fuel Tank..................................... 46 Electrical System Maintenance ........................... 47 Servicing the Battery......................................... 47 Servicing the Fuses .......................................... 48 Jump-Starting the Machine............................... 48 Drive System Maintenance .................................. 50 Checking the Seat Belt .....................................
Preparation Safety • Evaluate the terrain to determine what accessories Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions, and pay attention to the safety alert symbol, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instructions may result in personal injury or death.
Maintenance and Storage Make the necessary repairs before resuming operation. • Disengage drives, set the parking brake, shut off • Keep your hands and feet away from the cutting the engine, and remove the key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing the machine. unit. • Look behind and down before backing up to ensure a clear path. • Park the machine on a level surface. • Keep pets and bystanders away from an operating machine.
Service Toro Mower Safety • Do not store the machine or a fuel container inside The following list contains safety information specific to Toro products and other safety information that you must know. where there is an open flame, such as near a water heater or furnace. • Keep the nuts and bolts tight, especially the This product is capable of amputating hands and feet, and of throwing objects. Always follow all safety instructions to avoid serious injury or death. blade-attachment bolts.
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 lost. 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 the seat belt when the roll bar is down. 3.
decal115-9625 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged decal116-1716 decal117-0346 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 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. 9. Neutral 10. Operator-presence switch decal117-3848 117-3848 decal116-4858 116-4858 1.
decal117-3864 117-3864 1. Read the Operator’s Manual. 2. Fill to bottom of filler neck; warning—do not overfill the tank. decal126-4398 126-4398 1. Read the Operator’s manual 2. Lock 3. Unlock decal121-7586 121–7586 1. Fast 2. Variable speed control 3. Slow 4. Power takeoff (PTO) 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.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal132-5063 132-5063 1. Cam lock 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking 7. Wear eye protection; explosive gases can cause blindness and other injuries. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection. 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 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 g029631 Figure 4 1. Side-discharge deflector 8. Rear-shock assembly 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. Front-shock assembly 1. PTO Switch 4. Hour meter/Safety-interlock display/Fuel gauge 2. Throttle control 5. Ignition switch 3. Malfunction-indicator light (MIL) 6.
Safety-Interlock Indicators Blade-Control Switch (PTO) There are symbols on the hour meter and they indicate with a black triangle that the interlock component is in the correct position (Figure 6). Use the blade-control switch (PTO) to engage the electric clutch and drive the mower blades. Pull the switch up to engage the blades and release. To disengage the blades, push the blade-control switch (PTO) down or move a motion-control lever into the NEUTRAL-LOCK position.
Specifications Operation Note: Specifications and design are subject to Note: Determine the left and right sides of the machine from the normal operating position. change without notice. Width Without Deck 135 cm (53 inches) Adding Fuel Deflector Up 157 cm (62 inches) • For best results, use only clean, fresh (less than Deflector Down 192 cm (76 inches) • Length Roll Bar Up 211 cm (83 inches) Roll Bar Down 215 cm (85 inches) Height Roll Bar Up Roll Bar Down 179 cm (71 inches) 127.
Add the correct amount of gasoline stabilizer/conditioner to the gasoline. DANGER In certain conditions during fueling, static electricity can be released, causing a spark that can ignite the gasoline vapors. A fire or explosion from gasoline can burn you and others and can damage property. • Always place gasoline containers on the ground away from your vehicle before filling.
Checking the Engine-Oil Level 3. Lower the roll bar to the down position (Figure 8). 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 41). 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.
Entering the Operating Position DANGER Operating the machine while the roll bar is down may lead to serious injury or death in the event of a rollover. Use the mower deck as a step to get into the operating position (Figure 9). Always keep the roll bar in the fully raised and locked position and use the seat belt. g029797 Figure 9 1. Mower deck g000963 Figure 10 1. Safe Zone—use the machine here on slopes less than 15 degrees or flat areas. 2.
Operating the Parking Brake Operating the Mower Blade-Control Switch (PTO) Always set 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. Setting the Parking Brake Engaging the Blade-Control Switch (PTO) WARNING Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
g008946 Figure 16 Operating the Ignition Switch 1. g008948 Figure 18 Turn the ignition key to the START position (Figure 17). 1. On 2. Off Note: When the engine starts, release the key. Starting and Shutting Off the Engine Important: Do not engage the 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.
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 ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes. g036779 Figure 19 6. 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.
Testing the Safety-Interlock System Using the Safety-Interlock System Service Interval: Before each use or daily CAUTION 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.
Driving Forward or Backward Driving Forward Note: The engine shuts off if you move the traction-control levers with the parking brake engaged. The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Always operate in the full throttle position when mowing. To stop, pull the motion-control levers to the NEUTRAL position. CAUTION Machine can spin very rapidly.
Driving Backward 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 25). g008953 Figure 25 Shutting Off the Machine To shut off the machine, move the motion-control levers to neutral and then to the NEUTRAL-LOCK position, disengage the blade-control switch (PTO), and turn the ignition key to the OFF position. Set the parking brake when you leave the machine; refer to Setting the Parking Brake (page 20).
Adjusting the Height-of-Cut Pin Adjust the height-of-cut from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by moving the clevis pin into different hole locations. g008955 Figure 26 Transport-Lock Positions 1. Transport lock 3. UNLOCK position—The mower deck does not lock into the transport position. 2. LOCK position—The mower deck locks into the transport position. 26 1. Move the transport lock to the LOCK position. 2.
Adjusting the Anti-Scalp Rollers Whenever you change the height of cut, 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 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. g029840 Figure 27 1. Deck-lift pedal 3. Transport lock 2. Height-of-cut pin g029955 Figure 28 1. Anti-scalp roller 4. Flange nut 2.
Adjusting the Flow-Baffle-Cam Locks For Machines with Flow-Baffle Locks Only You can adjust the mower-discharge flow for different types of mowing conditions. Position the cam locks and baffle to achieve the best quality of cut. Note: Certain models have nuts and bolts in place of g029956 Figure 29 1. Anti-scalp roller 3. Flange nut 2. Bushing 4. Bolt the flow-baffle locks. 1.
Positioning the Flow Baffle Position B The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and height of grass. Use this position when bagging. Always align it with the blower opening. Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position A This is the full rear position. Use this position for the following. • Short, light grass mowing conditions. • Dry conditions. • Smaller grass clippings.
Adjusting the 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. The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. Adjusting the rear 2-shock assemblies is the easiest and quickest adjustment for changing the suspension system. Position the suspension system where you are most comfortable.
Adjusting the Front-Shock Assembly Adjust the rear-shock assemblies (Figure 37). The front-shock assembly is set at the middle position and is normally not adjusted. To adjust the front-shock assembly, open the floor pan and adjust it by using a spanner wrench (Toro Part No. 132-5069) or slip-joint pliers (Figure 38). g030024 g030049 Figure 38 1. Middle position 3. Soft ride 2.
Note: Make sure that the release valves are in the fully horizontal position when operating the machine, or severe damage to the hydraulic system could occur. 1. Disengage the blade-control switch (PTO) and turn the ignition key to off. Move the levers to the NEUTRAL-LOCK position and apply the parking brake. Remove the key. 2. Rotate the release-valve levers vertically to push the machine (Figure 39).
Transporting the Machine Loading the Machine Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury. Use extreme caution when loading or the unloading machine onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure.
WARNING Loading a machine onto a trailer or truck increases the possibility of a tip-over and could cause serious injury or death. • Use extreme caution when operating a machine on a ramp. • Ensure that the ROPS is in the up position and use the seat belt when loading or unloading the machine. Ensure that the ROPS clears the top of an enclosed trailer. • Use only a full-width ramp; do not use individual ramps for each side of the machine.
Cutting Long Grass Operating Tips If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST throttle position.
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 (check every time you remove or replace a brake component). After the first 250 hours • Change the hydraulic filters and hydraulic fluid. Before each use or daily • • • • • • • • Check the safety system. Check the engine-oil level. Check the seat belt.
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. Lubrication Adding Light Oil or Spray Lubrication Grease more frequently when operating conditions are extremely dusty or sandy. Service Interval: Every 100 hours Grease Type: No. 2 lithium or molybdenum-base grease 1.
Greasing the Mower 5. Grease the drive-belt idler arm (Figure 45). Service Interval: Every 50 hours—Grease the mower-deck spindles and idler arm. 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). 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. 2.
Lubricating the Caster-Wheel Hubs 12. Insert the second bearing and new seal into the wheel. 13. Apply a thread-locking compound to the second spacer nut and thread it onto the axle with the wrench flats facing outward. 14. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen the nut, then torque it to 2 to 3 N∙m (20 to 25 in-lb). Service Interval: Yearly 1. Shut off the engine, wait for all moving parts to stop, remove the key, and engage the parking brake.
Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. Keep hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces. Servicing the Air Cleaner g030481 Figure 49 Service Interval: Every 150 hours Every 300 hours/Yearly (whichever comes first)—Replace the primary air filter (more often in dusty or sandy conditions). 1. Cover 2. Primary filter 5. Air-inlet screen 6. Cover 3. Inner filter 4. Air-cleaner body 7.
Installing the Filters Servicing the Engine Oil Important: To prevent engine damage, always Oil Type: Detergent oil (API service class SL, SM, SN, or higher) operate the engine with both air filters and the cover installed. 1. Oil Capacity: with a filter change, 1.9 L (2.0 US qt); with no filter change, 1.6 L (1.7 US qt) If you are installing new filters, check each filter for shipping damage. Viscosity: See the table below. Note: Do not use a damaged filter. 2.
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. g029644 Note: This warms the oil so that it drains better. 2. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely. 3.
5. Changing the Engine-Oil Filter Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 53). Service Interval: Every 200 hours (more often in dirty or dusty conditions). Note: Change the engine oil filter more frequently when operating conditions are extremely dusty or sandy. 1. Drain the oil from the engine; refer to Changing the Engine Oil (page 42). 2. Change the engine oil filter (Figure 54).
Removing the Spark Plug Servicing the Engine-Oil Cooler Service Interval: Every 200 hours 1. Keep the oil cooler free of debris by cleaning the fins with a brush. 2. Remove the bolts holding the oil cooler to the engine housing. 3. Clean the inside of the oil cooler with a brush. 4. Install the oil cooler to the engine housing. 1. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 2.
Installing the Spark Plug Tighten the spark plug(s) to 24.4 to 29.8 N∙m (18 to 22 ft-lb). g029646 g027478 Figure 57 5. Install the left hydraulic unit shroud (Figure 56). g027735 Checking the Spark Plug Figure 59 Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. Checking the Spark Arrester (if Equipped) If you see light brown or gray on the insulator, the engine is operating properly.
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 60 This machine contains an electronic fuel-injection system. It controls the fuel flow under different operating conditions. 1. Fuel filter 2.
Electrical System Maintenance 3. Disconnect the negative battery cable (black) from the negative (-) battery terminal (Figure 61). 4. Servicing the Battery Slide the red terminal boot off the positive (+) battery terminal and remove the positive (red) battery cable (Figure 61). 5. Remove the wing nut securing the battery clamp (Figure 61). 6. Remove the clamp (Figure 61). 7. Remove the battery (Figure 61).
Charging the Battery Servicing the Fuses The electrical system is protected by fuses. It requires no maintenance, however, if a fuse blows check the component and circuit for a malfunction or short. WARNING Charging the battery produces gasses that can explode. Never smoke near the battery and keep sparks and flames away from 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).
DANGER Jump-starting a weak battery that is cracked, frozen, or has a low electrolyte level or an open/shorted battery cell can cause an explosion, resulting in serious personal injury. Do not jump-start a weak battery if these conditions exist. 2. Make sure that the booster battery is a good and fully charged lead-acid battery at 12.6 V or greater. g012785 Figure 64 Note: Use properly sized jumper cables with short lengths to reduce voltage drop between systems.
Drive System Maintenance Checking the Seat Belt Service Interval: Before each use or daily Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged. Checking the Rollover-Protection-System (ROPS) Knobs Service Interval: Before each use or daily WARNING To avoid injury or death from rollover: keep the roll bar in the fully raised locked position and use the seat belt. Ensure that the seat is secured to the machine.
Adjusting the Tracking 1. Disengage the blade-control switch (PTO). 2. Drive to an open, flat area and move the motion-control levers to the NEUTRAL-LOCK position. Checking the Tire Pressure Service Interval: Every 50 hours/Monthly (whichever comes first) 3. Move the throttle midway between the FAST and SLOW positions. Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut.
Checking the Wheel Hub Slotted Nut Adjusting the Caster-Pivot Bearing Service Interval: After the first 100 hours Service Interval: Every 500 hours/Yearly (whichever comes first) 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 the wheel hub. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. 2.
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, you can remove the shim to extend the clutch life. 5. Verify that 12 V is present at the clutch connector when the you engage the blade-control switch (PTO). 6. Measure the gap between the rotor and armature. If the gap is greater than 1 mm (0.04 inch), proceed with the following steps: A.
E. F. Using a 0.010 inch thick-feeler gauge, verify that a gap is present between the rotor and armature face on both sides of the brake pole as shown in Figure 75 and Figure 76. Perform the following safety check: i. Sit on the seat and start the engine. ii. Make sure that the blades do not engage when the blade-control switch (PTO) is in the OFF position and the clutch is disengaged.
Cleaning the Engine Cooling Fins and Shrouds Cooling System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) Cleaning the Engine Screen and Engine-Oil Cooler 1. Disengage the blade-control switch (PTO) and set the parking brake. Service Interval: Before each use or daily 2. Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 77).
Brake Maintenance Cleaning the Hydraulic Units Adjusting the Parking Brake Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO) 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. Move the seat forward. 4. Clean the debris and grass from the hydraulic units (Figure 79). 5. Position the seat. Service Interval: After the first 100 hours Every 500 hours thereafter 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 g026961 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake. 2.
g027730 Figure 83 Replacing the Hydraulic-Pump Drive Belt g017627 Figure 82 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. Disengage the blade-control switch (PTO) 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. Remove mower belt; refer to Replacing the Mower Belt (page 57). 4.
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. 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. Loosen the bolts and flange nuts installed in the levers (Figure 85). 4.
Note: The switch is a part of the seat assembly. 4. g009195 Figure 86 5. If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Neutral-Lock Pivot (page 62). Adjusting the Motion-Control Linkage The pump-control linkages are located on either side of the fuel tank, below the seat. Rotate the pump linkage with a 1/2 inch wrench for fine-tuning adjustments so that the machine does not move in neutral. Make any adjustments for neutral positioning only.
5. Start the engine. 14. Note: Engage the parking brake and move the motion-control levers out before starting the engine. You do not need to be in the seat because of the jumper wire being used. Run the engine at full throttle and release the brake. 6. Run the machine at least 5 minutes with the motion-control levers at full forward speed to bring the hydraulic fluid up to operating temperature. 7. Bring the motion-control levers into the NEUTRAL position. 8.
Adjusting the Motion-Control Neutral-Lock Pivot Hydraulic System Maintenance Servicing the Hydraulic System You can adjust the flanged nut to obtain the desired motion-control lever resistance when you move them to the NEUTRAL-LOCK position. See Figure 89 for adjustment options. Hydraulic Fluid Type: Toro® HYPR-OIL™ 500 hydraulic fluid or Mobil® 1 15W-50. 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel. Important: Use the fluid specified.
Replacing the Hydraulic Filters and Hydraulic Fluid Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic 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). To replace the hydraulic fluid, you need to remove the filters.
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 set 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 the pressure of the drive tires.
11. Fine-tune the adjuster screw by turning it to get 7.6 mm (3 inch) height (Figure 95). Note: To increase the height, turn the adjuster screw clockwise; to decrease the height, turn it counterclockwise. g029840 Figure 93 3. Transport lock 1. Deck-lift pedal 2. Height-of-cut pin 6. Insert the height-adjustment pin into the 7.6 cm (3 inch) height-of-cut location. 7. Release the transport lock and allow the deck to lower to the cutting height. 8. Raise the discharge chute. 9.
Servicing the Cutting Blades 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. To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, keep extra blades on hand.
Removing the Blades Checking for Bent Blades 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and 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. Rotate the blades until the ends face forward and backward (Figure 99). 1. Hold the blade end using a rag or a thickly padded glove. 4.
Installing the Blades Sharpening the Blades 1. 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 101). Install the blade onto the spindle shaft (Figure 103). Note: Maintain the original angle. Important: The curved part of the blade Note: The blade retains balance if you remove must point upward toward the inside of the mower to ensure proper cutting. the same amount of material from both cutting edges. 2. Install the spring disk and blade bolt (Figure 103).
Removing the Mower Deck Before servicing or removing the mower deck, lock out the spring-loaded deck arms. WARNING Deck-lift-arm assemblies have stored energy. Removing the deck without releasing the stored energy can cause serious injury or death. Do not attempt to disassemble the deck from the front frame without locking out the stored energy. 1. Shut off the engine, wait for all of the moving parts to stop, remove the key, and engage parking brake. 2.
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, mulch plate, grass deflector, or bagger. 1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 106). 2. Remove the damaged or worn grass deflector (Figure 106). g029652 Figure 105 1.
Cleaning Storage Cleaning under the Mower Cleaning and Storage 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. 1.
B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). C. Shut off the engine, allow it to cool, and drain the fuel tank; refer to Servicing the Fuel Tank (page 46). D. Restart the engine and run it until it stops. E. Dispose of fuel properly. Recycle as per local codes. Important: Do not store stabilizer/conditioned fuel over 90 days. 13. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 14.
Troubleshooting Problem The malfunction indicator light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Turn the engine off and let it cool. 2. There is old gas in the gas tank. 3. The fuel-shutoff valve is not open completely. 4. The air cleaner is dirty. 2. Use new gas. 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 left or right (with levers fully forward). The machine does not drive. There is abnormal vibration. The machine produces an uneven cutting height. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6.
Problem The clutch does not engage. Possible Cause Corrective Action 1. The fuse is blown. 1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. 2. There is low voltage supply at the clutch. 2. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. 3. Replace the clutch. 4. Repair or replace the clutch lead wire or electrical system.
GND BK BK + - A C FUEL SENDER S B BU PK (PTO SWITCH) SW2 PK PK 2 3 BN BN BN V 4 5 BK BK U2 BK F4 PK 7 4 9 HOUR METER 7 W PK 12 OR 10 T SW6 (BRAKE) GND 15A 6 2 3 Y 11 LTGR SW4 (NEUT_L) BN 8 B PTO CLUTCH TVS DIODE BK A BN F3 SW5 (NEUT_R) PTO 1 PK FUEL_SOLENOID NEUTRAL 8 SEAT OR BRAKE 5 8 4 7 10A KEY_A 1 GN SW7 (SEAT) BN PK OR GY R OR R GY PK PK GY V SW1 (IGNITION) 2 5 1 3 B I S R 5 GN 2 OPTIONAL ACCESSORIES FUEL GROUND B+ KEY_S 76 MAGNETO
Notes:
Notes:
The Toro Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to the original purchaser to repair the Toro Products listed below if defective in materials or workmanship.
