Form No. 3449-597 Rev A 60in TITAN® MAX Riding Mower Model No. 76601—Serial No. 400000000 and Up Model No. 76602—Serial No. 400000000 and Up Register at www.Toro.com.
its intended use could prove dangerous to you and bystanders. 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.
• Warning indicates a potentially hazardous • Recommended Maintenance Schedule(s) ........... 32 Lubrication .......................................................... 33 Greasing the Machine....................................... 33 Engine Maintenance ........................................... 34 Engine Safety ................................................... 34 Servicing the Air Cleaner .................................. 34 Servicing the Engine Oil....................................
Safety This machine has been designed in accordance with ANSI B71.1-2017. 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 or death. • Read and understand the contents of this Operator’s Manual before starting the engine. • Keep bystanders and children away. • Do not allow children or untrained people to operate or service the machine.
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. decaloemmarkt Manufacturer's Mark 1. This mark indicates that the blade is identified as a part from the original machine manufacturer. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away from the battery. 2.
decal115-9625 115-9625 1. Parking brake—disengaged 2. Parking brake—engaged decal117-1194 117-1194 1. Belt routing 2. Engine decal133-8062 decal116-5610 133-8062 116-5610 1. Hour meter 2. Power take-off (PTO) 4. Neutral 5. Operator presence switch 3. Parking brake 6. Battery decal126-4363 126-4363 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. Shut off the engine and remove the key before adjusting, servicing or cleaning the machine. decal116-8588 116-8588 1.
decal130-0765 130-0765 1. Read the Operator's Manual. 3. Remove the key before performing maintenance. 2. Height-of-cut selection decal126-4784 126-4784 1. Height of cut decal132-0872 132-0872 1. Thrown object hazard—keep bystanders away from the machine. 3. Severing hazard of hand or foot—keep away from moving parts. 2. Thrown object hazard, raised deflector—do not operate the machine with an open deck; use a bagger or a deflector. 4.
Decal 137-9240 is for machines not equipped with the optional work lights. decaltransportlock Transport Lock 1. Height of cut 2. Pull up to unlock the transport lock. decal137-9240 137-9240 1. Choke 2. Work light 3. Fast 4. Slow Decal 145-4618 is for machines equipped with work lights. decal126-6194 126-6194 1. Traction control 2. Fast 3. Slow decal145-4618 4. Neutral 5. Reverse 145-4618 1. Choke 2. Work light 9 3. Fast 4.
decal126-6183 126-6183 1. Traction control 2. Fast 3. Slow 4. Neutral 5. Reverse decal126-8383 126-8383 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.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g368671 Figure 5 g368672 Figure 4 1. Height-of-cut deck-lift pedal 7. Work lights (standard on Model 76602; optional kit on Model 76601) 2. Height-of-cut positions 8. Fuel cap 3. Transport lock 9. Parking-brake lever 4. Controls 5. Motion-control levers 6. Roll bar 1. Key switch 5. Choke control 2. Blade-control switch (power takeoff) 6.
Light Switch Motion-Control Levers Applicable Models Only Use the motion-control levers to drive the machine forward, reverse, and turn either direction (Figure 4). Press the light switch forward to turn on the work lights (Figure 5). Neutral-Lock Position Press the light switch rearward to turn off the work lights. Move the motion-control levers outward from the center to the NEUTRAL-LOCK position when exiting the machine (Figure 23).
Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Note: Determine the left and right sides of the machine from the normal operating position. – To prevent a static charge from igniting the fuel, remove the machine from the truck or trailer and refuel it on the ground, away from all vehicles.
Adding Fuel Recommended Fuel Type Unleaded gasoline Minimum octane rating 87 (US) or 91 (research octane; outside the US) Ethanol No more than 10% by volume Methanol None MTBE (methyl tertiary butyl ether) Less than 15% by volume Oil Do not add to the fuel Use only clean, fresh (no more than 30 days old), fuel from a reputable source.
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. g004954 Figure 8 1. Full-down position WARNING There is no rollover protection when the roll bar is in the down position. 2. Down position with the bagger installed Important: Ensure that you secure the rear part of the seat with the seat latch.
Using the Safety-Interlock System 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. WARNING If the safety-interlock switches are disconnected or damaged, the machine could operate unexpectedly, causing personal injury. • Do not tamper with the interlock switches.
Positioning the Seat • Do not mow in reverse unless it is absolutely The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable (Figure 11). • • • • • g027632 Figure 11 During Operation • During Operation Safety • • General Safety • • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage. • • Use your full attention while operating the machine.
• Be aware of the mower discharge path and direct the discharge away from others. Avoid discharging material against a wall or obstruction because the material may ricochet back toward you. distance (twice the width of the machine) between the machine and any hazard. Use a walk-behind machine or a hand trimmer to mow the grass in these areas.
Rollover Protection System (ROPS) Safety Entering the Operator’s Position • The ROPS is an integral safety device. Do not Use the mower deck as a step to get into the operator’s position (Figure 14). remove any of the ROPS components from the machine. • Ensure that the seat belt is attached and that you can release it quickly in an emergency. • Keep the roll bar in the fully raised and locked position and always wear your seat belt whenever the roll bar is up.
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. Note: A warm or hot engine may not require choking. 1. 2. Pull up the choke knob to engage the choke before using the key switch (Figure 20). Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.
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 23 1. Motion-control levers—NEUTRAL-LOCK position 4. Reverse 2. Center, unlocked position 5. Front of the machine 3.
Driving the Machine The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves. 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.
Using the Side Discharge The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. DANGER Without a grass deflector, discharge cover, or a complete grass-catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death. • Never remove the grass deflector from the mower deck because the grass deflector routes material down toward the turf.
4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, and insert the pin (Figure 27). Adjusting the Anti-Scalp Rollers 5. Push on the deck lift, pull up on the transport lock knob, and slowly lower the mower deck. Whenever you change the height of cut, adjust the height of the anti-scalp rollers. Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas. 1.
Stopping the Machine Operating Tips If you must stop the forward motion of the machine while mowing, a clump of grass clippings may 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. Maximizing Air Circulation For best mowing and maximum air circulation, operate the engine at the FAST position.
Using the Fuel-Shutoff Valve After Operation After Operation Safety Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 29). General Safety Ensure that the fuel-shutoff valve is open when starting the engine. • Engage the parking brake, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operator’s position. Allow the machine to cool before servicing, adjusting, fueling, cleaning, or storing it.
Using the Drive-Wheel Release Valves WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel release valves. WARNING The engine and hydraulic-drive units can become very hot. Touching a hot engine or hydraulic-drive units can cause severe burns.
Transporting the Machine 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. Refer to your local ordinances for trailer and tie-down requirements.
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 31). 4. Back the machine up the ramp (Figure 32). 2. g028043 Figure 32 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 • Check the parking brake operation frequently. • Maintenance Safety • • If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance. • • Before you leave the operator’s position, do the following: • – Park the machine on a level surface. – Disengage the drives. • – Engage the parking brake. – Shut off the engine and remove the key.
Maintenance Service Interval Every 500 hours Monthly Yearly or before storage Maintenance Procedure • Replace the spark plugs and set the gap. • Check the parking brake adjustment. • After the initial change—change the hydraulic-system filters and fluid when using Toro® HYPR-OIL™ 500 fluid. (Change it more often under dirty or dusty conditions) • Check the battery charge. • Paint chipped surfaces. • Complete all the procedures in the Storage chapter.
Engine Maintenance Engine Safety • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Allow engine components to cool before performing maintenance. • Do not change the engine governor speed or overspeed the engine. g305607 Servicing the Air Cleaner Figure 34 2. Retaining clamp 1. Cover Service Interval: Every 25 hours—Clean the air-cleaner foam element (more often in dusty, dirty conditions). 5.
Servicing the Paper Air-Cleaner Element Servicing the Engine Oil Service Interval: Every 100 hours or yearly, whichever comes first—Replace the paper air-cleaner element (more often in dirty or dusty conditions). Engine-Oil Specifications 1. Oil Type: Detergent oil (including synthetic) of API service SJ or higher Crankcase Capacity: 1.9 L (64 fl oz) with oil filter Clean the paper element by tapping it gently to remove dust. Viscosity: See the table below.
g225280 Figure 38 g365791 Figure 37 5. Note: Ensure that the oil-filter gasket touches Changing the Engine Oil and Oil Filter the engine and then turn the filter an extra 3/4 turn. Service Interval: Every 100 hours or yearly, whichever comes first—Change the engine oil and oil filter (more often in dirty or dusty conditions). 1. Park the machine on a level surface to ensure that the oil drains completely. 2.
g365790 Figure 40 7. g027477 Figure 39 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 40). 37 Dispose of the used oil at a recycling center.
Servicing the Spark Plug Service Interval: Every 100 hours or yearly, whichever comes first—Check the spark plugs. Every 500 hours—Replace the spark plugs and set the gap. Ensure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.
Fuel System Maintenance DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. g305646 Refer to Fuel Safety (page 14) for a complete list of fuel related precautions. Replacing the In-Line Fuel Filter Service Interval: Every 100 hours—Replace the in-line fuel filter. Never install a dirty filter after removing it from the fuel line. 1.
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 45. 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 1. Charging the battery produces gasses that can explode. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 45). 2. Never smoke near the battery and keep sparks and flames away from the battery. Install the positive (red) battery cable to the positive (+) battery terminal. 3. Install the negative (black) battery cable and ground wire to the negative (-) battery terminal. 4.
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. 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. 3. g035859 Figure 48 Right control lever shown Move the throttle midway between the FAST and SLOW positions. 4.
Checking the Tire Pressure Cooling System Maintenance 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.
Brake Maintenance Adjusting the Parking Brake Service Interval: Every 500 hours Note: Perform this procedure whenever you remove or replace a brake component. 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. Set up the machine to be pushed by hand. Refer to Using the Drive-Wheel Release Valves (page 29). 4.
9. Belt Maintenance Rotate the brake-linkage shaft until the end aligns with the hole in the lever. • Shorten the linkage by turning it clockwise. Inspecting the Belts • Lengthen the linkage by turning it counterclockwise. 10. Insert the brake-linkage shaft into the parking-brake hole and secure with the cotter pin. Repeat step 5 and adjust if necessary. 11. When adjustment is complete, remove the jack stands or equivalent support and lower the machine. 12.
7. Route the new belt around the engine pulley and mower pulleys (Figure 54). 8. Using a spring-removal tool (Toro Part No. 92-5771), install the idler spring over the deck hook and place tension on the idler pulley and the mower belt (Figure 54). 9. Tighten the nut securing the wire form to the idler pulley (Figure 53). Note: Position the wireform against the idler arm as shown in Figure 53. 10. Install the pulley covers. g334161 Figure 53 Replacing the Hydraulic Pump-Drive Belt 3.
Controls System Maintenance Adjusting the Control-Handle Position If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage (page 48). Adjusting the Height You can adjust the motion control levers higher or lower for maximum comfort. g036859 Figure 56 1. Idler pulley 4. Pump-drive belt 2. Idler-spring post 5. Right hydraulic-pump pulley 3. Engine pulley 6. Left hydraulic-pump pulley 9. 10. Install the clutch stop (Figure 55). 1.
Adjusting the Motion-Control Linkage Adjusting the Tilt 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 upper bolt holding the control lever to the control arm shaft. 4. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position. 5.
11. Hydraulic System Maintenance Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse (Figure 59). Hydraulic System Safety • Seek immediate medical attention if fluid is injected into skin. Injected fluid must be surgically removed within a few hours by a doctor.
Checking the Hydraulic Fluid Level after purging. Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system. Service Interval: Before each use or daily 1. Allow the hydraulic fluid to cool down. Check the oil level when the fluid is cold. 2. Check expansion reservoir and if necessary add Toro® HYPR-OIL™ 500 hydraulic fluid to the FULL COLD line. Removing Hydraulic-System Filters 1.
Installing the Hydraulic-System Filters 1. Apply a thin coat of hydraulic fluid on the surface of the rubber seal of each filter. 2. Turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 3/4 to 1 full turn. 3. Repeat for the opposite filter. 4. Install the filter guards over each filter that you previously removed. 5. Use the 3 screws to secure the filter guards. 6. Verify that the vent plugs are removed before adding the fluid. 7.
Mower Deck Maintenance Bleeding the Hydraulic System 1. Raise the rear of machine and support it with jack stands (or equivalent support) just high enough to allow the drive wheels to turn freely. Blade Safety • Inspect the blades periodically for wear or damage. • Use care when checking the blades. Wrap the blades or wear gloves, and use caution when servicing the blades. Only replace or sharpen the blades; never straighten or weld them.
g006530 Figure 64 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 66 1. Blade (in position for measuring) Checking for Bent Blades 2. Level surface 3. Measured distance between blade and the surface (A) Note: The machine must be on a level surface for the following procedure. 4. 1. Raise the mower deck to the highest height-of-cut position. 2.
g014973 Figure 68 1. Opposite blade edge (in position for measuring) 2. Level surface 3. Second measured distance between blade and surface (B) A. g017443 If the difference between A and B is greater than 3 mm (1/8 inch), replace the blade with a new blade; refer to Removing the Blades (page 54) and Installing the Blades (page 55). Figure 69 3.
g000553 Figure 71 1. Blade 3. 4. Position the mower deck in the transport-lock position. 5. Carefully rotate the blades from side to side. 6. Measure between the blade tip and the flat surface (Figure 72). If both measurements are not within 5 mm (3/16 inch), adjust the leveling; continue with this procedure. 2. Balancer Repeat this procedure until the blade is balanced. Installing the Blades 1. Install the blade onto the spindle shaft (Figure 69).
skirt; 1 on each side of the cutting deck (Figure 74). 10. Set the height-of-cut lever to the 3 inch (76 mm) position. 11. Place 2 blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets or welds. g035851 Figure 75 g038090 Figure 74 Bottom view 1. Block—7.3 cm (2.87 inches) 2. Welds Block Height and Rake Table Deck Size Front Block Height Rake All mower decks 7.3 cm (2.87 inches) 4.8 to 6.4 mm (3/16 to 1/4 inch) 12.
Removing the Mower 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 disconnect the spark-plug wires from the spark plugs. 3. Lower the mower to the 76 mm (3 inches) height-of-cut position. 4. Remove the mower belt from the engine pulley; refer to Replacing the Mower Belt (page 45). 5.
Replacing the Grass Deflector 3. Position the new discharge deflector with the bracket ends between the welded brackets on the deck as shown in Figure 79. Service Interval: Before each use or daily—Inspect the grass deflector for damage. 4. Install the spring onto the straight end of the rod. 5. Position the spring on the rod as shown in Figure 79 so that the shorter spring end comes from under the rod before the bend and going over the rod as it returns from the bend. 6.
Cleaning Cleaning under the Mower Deck Service Interval: After each use 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. Disposing of Waste Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 52). Storage Safety 13. Prepare the machine for storage when non-use occurs over 30 days. Prepare the machine for storage as follows: • Shut off the engine, remove the key, and wait for all moving parts to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. A.
Troubleshooting Problem The engine overheats. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The oil level in the crankcase is low. 3. The cooling fins and air passages under the engine-blower housing are plugged. 4. The air cleaner is dirty. 2. Add oil to the crankcase. 3. Remove the obstruction from the cooling fins and air passages. 5. Dirt, water, or stale fuel is in the fuel system. The starter does not crank.
Problem The machine does not drive. The machine vibrates abnormally. The cutting height is uneven. The blades do not rotate. Possible Cause 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. The idler spring is broken or missing. 5. The hydraulic fluid level is low or too hot. 2. Change the belt. 3. Change the belt. 4. Replace the spring. 5. Add hydraulic fluid to the reservoirs or let it cool down.
Schematics g351785 Electrical Schematic (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.
