Form No. 3449-184 Rev A Z Master® Professional 2000 Series Riding Mower With 48in, 52in, or 60in TURBO FORCE® Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 77248—Serial No. 77260—Serial No. 77280—Serial No. 77282—Serial No. 77284—Serial No. 77287—Serial No. 77290—Serial No. 77293—Serial No. 77299—Serial No.
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.
safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution. serial numbers on the product. Write the numbers in the space provided. Important: With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information. • Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Adjusting the Side-to-Side Leveling and the Blade Slope .................................................. 68 Removing the Mower Deck............................... 70 Replacing the Grass Deflector .......................... 71 Cleaning .............................................................. 72 Cleaning under the Mower Deck ....................... 72 Cleaning the Suspension System ..................... 72 Disposing of Waste........................................... 72 Storage .......................
Safety This machine has been designed in accordance with ANSI standard B71.4-2017. 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 5 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 decal106-5517 1. This mark indicates that the blade is identified as a part from the original machine manufacturer. 106-5517 1. Warning—do not touch the hot surface. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6.
decal109-6014 109-6014 1. Traction belt routing decal116-5610 116-5610 1. Hour meter 2. Power take-off (PTO) 4. Neutral 5. Operator presence switch 3. Parking brake 6. Battery decal112-3858 112-3858 1. Read the Operator's Manual. 3. Remove the key before adjusting the height of cut. 2. Read the Operator's Manual before performing maintenance. 4. Height-of-cut settings decal112-9028 decal116-8588 112-9028 116-8588 1. Warning—stay away from moving parts; keep all guards and shields in place. 1.
decal144-3778 144-3778 1. Choke 2. Fast 3. Slow 4. Headlights decal117-1194 117-1194 1. Belt routing 2. Engine decal126-4363 126-4363 decal133-8062 1. Cutting/dismemberment hazard, fan and entanglement hazard, belt. Shut off the engine and remove the key before adjusting, servicing or cleaning the machine. 133-8062 decal117-3848 117-3848 decal135-2310 135-2310 1. Thrown object hazard—keep bystanders away. 2.
Decal 131-1097 is for machines with Toro engines only. decal131-1097 131-1097 1. Oil drain decal126-4784 126-4784 1. Height of cut decal136-9024 136-9024 decal126-9939 126-9939 1. Read the Operator’s Manual 4. Grease point 1. Read the Operator’s Manual before performing maintenance. 2. Operating hours 5. Hydraulic-fluid level 3. Engine-oil level 6. Tire pressure 2. Fill to bottom of filler neck; warning–do not overfill the tank decalptosymbols PTO Switch Symbols 1. PTO–disengage 10 2.
decal126-8151 126-8151 1. Read the instructions before servicing or performing maintenance on the machine. 2. Time interval 4. Refer to the Operator's Manual for grease instructions. 5. Check the hydraulic-fluid level and refer to the Operator's Manual for further instructions. 6. Check the tire pressure. 3. Check the oil level. Decal 145-3668 is for machines with MyRide only. decal145-3668 145-3668 1. Fuel—full 3. Fuel—empty 2.
Decal 126-8383 is for machines without MyRide only. 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. 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 the conditions on that day and at that site.
Decal 132-0871 is for machines with MyRide only. 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 the conditions on that day and at that site.
Controls Product Overview Become familiar with all the controls before you start the engine and operate the machine. Control Panel g271171 Figure 7 1. Power point 5. Blade-control switch (power takeoff) 2. Choke control 6. Key switch 3. Throttle control 7. Light switch (for models with lights only)—optional kit for other models 4. Hour meter g336657 Figure 6 1. Height-of-cut deck-lift pedal 7. Shock assembly 2. Height-of-cut positions 8. Seat belt 3. Transport lock 9. Fuel cap 4.
Hour Meter Fuel-Shutoff Valve 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 8). Close the fuel-shutoff valve when transporting or storing the machine; refer to Using the Fuel-Shutoff Valve (page 33). g187133 Figure 8 1. Safety-interlock symbols 3. Battery light 2.
Specifications Note: Specifications and design are subject to change without notice.
Fuel Safety Operation • Fuel is extremely flammable and highly explosive. Note: Determine the left and right sides of the machine from the normal operating position. Before Operation Before Operation Safety General Safety • Do not allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
Adding Fuel Note: Do not fill the fuel tank completely full. The empty space in the tank allows the fuel to expand. Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
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. Using the Rollover-Protection System (ROPS) g004954 Figure 10 WARNING 1. Full-down position To avoid injury or death from rollover, keep the roll bar in the fully raised, locked position and use the seat belt. 2.
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 Adjusting the Rear-Shock Assemblies The seat can move forward and backward (Figure 13). Position the seat where you have the best control of the machine and are most comfortable. Machines with MyRide™ Suspension System Only The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable.
Using Attachments and Accessories Use only Toro approved attachments and accessories. If you add more than 1 accessory mount kit (i.e., bucket kit or universal mount kit) to both of the locations shown in Figure 17, add a front weight kit. Contact an Authorized Service Dealer for the front weight kit. g227752 g298130 Figure 17 1. Add a front weight kit when accessory mount kits are installed at both of these positions.
• Keep your hands and feet away from the cutting units. Keep clear of the discharge opening. • Do not mow with the discharge deflector raised, removed, or altered unless there is a grass-collection system or mulch kit in place and working properly. g229846 Figure 18 • Do not mow in reverse unless it is absolutely necessary. Always look down and behind you before moving the machine in reverse. 1. Wear hearing protection.
• Replace damaged ROPS components. Do not braking and steering. The machine can slide even if the drive wheels are stopped. repair or alter them. • There is no rollover protection when the roll bar • Remove or mark obstacles such as ditches, holes, is down. ruts, bumps, rocks, or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine. • Wheels dropping over edges, over steep banks, or into water can cause a rollover, which may result in serious injury or death.
Disengaging the Parking Brake Entering the Operator’s Position Use the mower deck as a step to get into the operator’s position (Figure 20). g192635 g029797 Figure 22 Figure 20 1. Step here. Operating the Parking Brake Always engage the parking brake when you stop the machine or leave it unattended. Engaging the Parking Brake Park the machine on a level surface.
Operating the Mower Operating the Choke Blade-Control Switch (PTO) Use the choke to start a cold engine. The blade-control switch (PTO) starts and stops the mower blades and any powered attachments. Engaging the Blade-Control Switch (PTO) 1. Pull up the choke knob to engage the choke before using the key switch (Figure 26). 2. Push down the choke knob to disengage the choke after the engine has started (Figure 26).
Starting the Engine Shutting Off the Engine Note: A warm or hot engine may not require choking. Note: Refer to Figure 43 to determine which engine you have. 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.
Shutting Off Toro Engines Using the Motion-Control Levers Note: Ensure the throttle is in the FAST position before shutting off the engine. g004532 Figure 30 g037049 Figure 29 1. Motion-control levers—NEUTRAL-LOCK position 4. Reverse 2. Center, unlocked position 5. Front of the machine 3. Forward Important: Make sure that the fuel-shutoff valve is closed before transporting or storing the machine to prevent fuel leakage. Engage the parking brake before transporting.
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 Adjusting the Height of Cut The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf. Using the Transport Lock 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. 1.
Adjusting the Height-of-Cut Pin Adjusting the Anti-Scalp Rollers The height of cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by relocating the clevis pin into different hole locations. 1. 2. Whenever you change the height of cut, adjust the height of the anti-scalp rollers. Move the transport lock to the LOCK position (Figure 33). Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas.
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 deck in uncut grass.
Using the Drive-Wheel Release Valves Using the Fuel-Shutoff Valve Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 36). WARNING Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. Ensure that the fuel-shutoff valve is open when starting the engine. Shut off the engine, remove the key, and allow all moving parts to stop before accessing the drive-wheel release valves.
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 38). 4. Back the machine up the ramp (Figure 39). g028043 Figure 39 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. Adjust and service it as required. • Never tamper with safety devices. Check their Maintenance Safety proper operation regularly. • Clean grass and debris from the cutting unit, • If you leave the key in the switch, someone could muffler, drives, grass catcher, and engine compartment to prevent fires. accidently start the engine and seriously injure you or other bystanders. Remove the key from the switch before you perform any maintenance.
Maintenance Service Interval Every 100 hours or yearly, whichever comes first Maintenance Procedure • For Toro engines—change the engine oil and oil filter (more often in dirty or dusty conditions). • For Toro engines—check the spark plug(s). Every 200 hours • For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). • For Toro engines—replace the spark plug(s).
Lubrication Greasing the Machine Service Interval: Every 25 hours—Grease the front caster axles (more often in dirty or dusty conditions). Every 50 hours—Grease the pump-idler pivot. Grease the machine more often in dirty or dusty conditions. Grease Type: No. 2 lithium or molybdenum grease 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 2.
Greasing the Caster-Wheel Hubs 13. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease. Service Interval: Yearly 14. Insert the second bearing and new seal into the wheel. 1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake. 15. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.
Engine Maintenance Servicing a Kawasaki® Engine Engine Safety This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 44, you have a Kawasaki engine. • 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. Important: Refer to your engine owner’s manual for additional maintenance procedures.
3. Carefully slide the primary filter over the safety filter (Figure 45). Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it. Important: Do not press on the soft, inside area of the filter. 4. g001883 Figure 45 1. Air-cleaner body 4. Air-cleaner cover 2. Primary filter 5. Safety filter 3. Latch 4. Clean the inside of the air-cleaner cover with compressed air. 5. Gently slide the primary filter out of the air-cleaner body (Figure 45).
Servicing the Engine Oil 3. Service Interval: Before each use or daily To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 47). Every 100 hours (more often in dirty or dusty conditions). Every 200 hours—For Kawasaki engines—change the engine-oil filter (more often in dirty or dusty conditions). Engine-Oil Specifications Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) g036856 Crankcase Capacity: 1.
3. Disengage the blade-control switch (PTO) and engage the parking brake. 4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 5. Drain the oil from the engine (Figure 48). 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 49). g036856 g235264 Figure 49 7. Start the engine and drive to a flat area. 8. Check the oil level again.
Servicing the Spark Plug(s) Service Interval: Every 100 hours 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. g036856 Type of Spark Plug: NGK® BPR4ES or equivalent Air Gap: 0.75 mm (0.03 inch) Removing the Spark Plug(s) 1.
Servicing a Toro Engine This section is only for machines with Toro engines. If your engine looks like the one shown in Figure 54, you have a Toro engine. g206628 Figure 52 Installing the Spark Plug(s) g296342 Figure 54 Servicing the Air Cleaner Service Interval: Every 250 hours—For Toro engines—replace the air filter (more often in dirty or dusty conditions). Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.
Servicing the Engine Oil Service Interval: Before each use or daily—For Toro engines—check the engine-oil level. After the first 5 hours/After the first month (whichever comes first)—For Toro engines—change the engine oil and filter. Every 100 hours or yearly, whichever comes first—For Toro engines—change the engine oil and oil filter (more often in dirty or dusty conditions). Engine-Oil Specifications g230914 Oil Type: Detergent oil (API service SF, SG, SH, SJ, or SL) Figure 55 1. Air-cleaner body 3.
g027799 g311705 Figure 57 Changing the Engine Oil and Oil Filter 1. Park the machine on a level surface to ensure that the oil drains completely. 2. Disengage the blade-control switch (PTO) 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. Drain the oil from the engine.
5. Change the engine-oil filter (Figure 59). Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn. g235264 Figure 60 7. Dispose of the used oil at a recycling center. Servicing the Spark Plug(s) Service Interval: Every 100 hours or yearly, whichever comes first—For Toro engines—check the spark plug(s). Every 200 hours/Every 2 years (whichever comes first)—For Toro engines—replace the spark plug(s). g027477 Figure 59 6.
Installing the Spark Plug(s) g036857 g027478 Figure 61 g027960 Figure 63 Checking the Spark Plug(s) Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks. Cleaning the Blower Housing 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.
Cleaning the Cooling System Checking the Spark Arrester 1. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. For Machines with a Spark Arrester 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Service Interval: Every 50 hours 3. Remove the air filter from the engine. 4. Remove the engine shroud. 5.
Replacing the Emissions-Air Intake Filter Fuel System Maintenance Service Interval: Every 500 hours 1. DANGER Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Remove the filter from the vent hose. 4. Insert a new filter into the end of the vent hose.
Electrical System Maintenance 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. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
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 65. 4. Install the battery in the machine and connect the battery cables; refer to Installing the Battery (page 54). Note: Do not run the machine with the battery disconnected; electrical damage may occur. g036853 g000960 Figure 66 g036855 Figure 65 Charging the Battery WARNING Charging the battery produces gasses that can explode.
Installing the Battery 1. Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 65). 2. 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. Note: For MyRide machines, ensure that the ground cable does not rub against the trailing arm or lower shock mount (Figure 68). g036858 Figure 68 1. Fuse cover 2.
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 69 Right control lever shown Move the throttle midway between the FAST and SLOW positions. 4.
Brake Maintenance Checking the Tire Pressure For Machines with Pneumatic Tires Only Adjusting the Parking Brake Service Interval: Every 50 hours/Monthly (whichever comes first) For machines with pneumatic tires only. Service Interval: Every 500 hours Note: Perform this procedure whenever you remove Maintain the air pressure in the 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.
9. Rotate the brake-linkage shaft until the end aligns with the hole in the lever. • Shorten the linkage by turning it clockwise. • Lengthen the linkage by turning it counterclockwise. g036752 Figure 71 1. Cotter pin 3. Brake linkage shaft 2. Parking brake 7. Check both spring lengths as shown in Figure 72. If an adjustment is necessary, turn the top nut clockwise to shorten the spring and counterclockwise to lengthen it. g036100 Figure 72 1. Top nut 3. 44 mm (1-3/4 inches) 2. Spring 8.
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. Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
9. Install the belt covers (Figure 76). 6. Remove the idler spring from the post (Figure 78). 7. Remove the existing belt from the hydraulic-pump-drive pulleys and the engine pulley. 8. Install the new belt around the engine pulley and the 2 hydraulic-pump pulleys (Figure 78). g027730 Figure 76 Replacing the Hydraulic Pump-Drive Belt 1. g036859 Figure 78 Park the machine on a level surface, disengage the blade-control switch (PTO), and engage the parking brake. 2.
Adjusting the Tilt 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 61). 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.
Adjusting the Motion-Control Linkage 11. Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse (Figure 81). Located on either side of the machine, below the seat, are the pump-control linkages. Rotating the end nut with a 1/2-inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.
Hydraulic System Maintenance 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. • Ensure that all hydraulic-fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.
2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Allow the engine to cool. 4. Locate the filter and guards on each transaxle-drive system (Figure 83). 5. Remove the 3 screws securing the filter guard and guard (Figure 83). 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.
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. g017625 Figure 85 1. Jacking points 2. g027477 Figure 84 3. Start the engine, move the throttle control ahead to the 1/2 throttle position, and disengage the parking brake. A. Move the bypass levers into the pushing the machine position.
4. Mower Deck Maintenance Check the fluid level in the expansion reservoir a final time. Add the specified fluid as until it reaches the FULL COLD line on the expansion reservoir. 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 86 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack g014973 Figure 88 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 90 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 67) and Installing the Blades (page 68). Figure 91 3.
g000553 Figure 93 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 94). 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 91).
A. Raise the deck to the transport position (12.7 cm or 5 inches). B. Slowly loosen the adjusting screw on the lift-assist spring until you can remove the screw (see Figure 96). Note: Save the screw for installation. g038090 Figure 97 Bottom view 2. Welds 1. Block—7.3 cm (2.87 inches) 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) 13. g035850 Figure 96 Rear discharge mower deck shown 1. Adjusting screw 14.
17. Ensure that the blocks fit snugly under the deck skirt and that all attachment bolts are tight 18. Continue leveling the deck by checking the front-to-rear blade slope. 19. Check the blades for levelness and repeat deck leveling procedure if necessary. 20. For 60-inch mower decks only: Removing the Mower Deck Before servicing or removing the mower deck, lock out the spring-loaded deck arms. 1.
Replacing the Grass Deflector WARNING An uncovered discharge opening could allow the machine to throw objects toward you or bystanders, resulting in serious injury. Also, contact with the blade could occur. Never operate the machine unless you install a mulch plate, discharge deflector, or grass collection system. 1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 100). 2. Remove the damaged or worn grass deflector (Figure 100). g015594 Figure 100 1.
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.
Storage 12. Check the condition of the blades; refer to Servicing the Cutting Blades (page 65). 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 g018479 Wire Diagram—Toro Engines (Rev.
g037072 Wire Diagram—Kawasaki Engines (Rev.
Notes:
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.
