Form No. 3409-767 Rev C Z Master® Professional 5000 or 6000 Series Riding Mower with 52in, 60in, or 72in TURBO FORCE® Side Discharge Mower Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 74906—Serial No. 74918—Serial No. 74926—Serial No. 74928—Serial No. 74930—Serial No. 78926—Serial No. 78928—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. Dealer or Toro Customer Service and have the model and serial numbers of your product ready.
Contents Servicing the Engine Oil.................................... 40 Servicing the Spark Plug................................... 42 Checking the Spark Arrester ............................. 44 Fuel System Maintenance ................................... 44 Servicing the Electronic Fuel-Injection System.......................................................... 44 Replacing the Low-Pressure Fuel Filter..............................................................
Safety Troubleshooting ...................................................... 71 Schematics ............................................................. 74 This machine has been designed in accordance with ANSI B71.4-2012. General Safety This product is capable of amputating hands and feet and of throwing objects. Always follow all safety instructions to avoid serious personal injury. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
Slope Indicator g011841 Figure 3 This page may be copied for personal use. 1. The maximum slope you can safely operate the machine on is 15 degrees. Use the slope chart to determine the degree of slope of hills before operating. Do not operate this machine on a slope greater than 15 degrees. Fold along the appropriate line to match the recommended slope. 2. Align this edge with a vertical surface, a tree, building, fence pole, etc. 3.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal58-6520 58-6520 decal106-2655 1. Grease 106-2655 1. Warning-do not touch or approach moving belts; remove the ignition key and read the instructions before servicing or performing maintenance. decal93-7818 93-7818 1.
decal110-2068 110-2068 1. Read the Operator's Manual. decal112-9028 112-9028 1. Warning—stay away from moving parts; keep all guards in place. decal107-3069 107-3069 1. Warning–there is no rollover protection when the roll bar is down. 2. To avoid injury or death from a rollover accident, keep the roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the seat belt when the roll bar is down. 3.
decal116-5988 116-5988 1. Parking brake—engaged 2. Parking brake—disengaged decal116-8726 116-8726 decal136-5508 136-5508 1. Read the Operator’s Manual for the recommended hyraulic fluid. 1. Belt routing decal116-1716 116-1716 1. Fuel 2. Empty 6. Hour meter 7. PTO 3. Half 8. Parking brake 4. Full 5. Battery 9. Neutral 10. Operator-presence switch decal117-0346 117-0346 1.
decal121-7586 121–7586 decal117-3848 117-3848 1. Fast 2. Variable-speed control 1. Thrown object hazard—keep bystanders a safe distance away from the machine. 3. Slow 4. Power takeoff (PTO) 2. Thrown object hazard, mower—do not operate the machine without deflector, discharge cover, or grass collection system in place. 3. Cutting/dismemberment of hand or foot—stay away from moving parts; keep all guards and shields in place. decal126-2055 126-2055 1. Wheel lug nut torque 129 N∙m (95 ft-lb) (4x) 2.
decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. decal127-0326 127-0326 1. Read the Operator's Manual. 3. Remove the key from the ignition and read the Operator's Manual before performing maintenance or servicing the machine. 1. Explosion hazard 6. Keep bystanders a safe distance away 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.
decal132-0871 132-0871 Note: This machine complies with the industry standard stability test in the static lateral and longitudinal tests with the maximum recommended slope indicated on the decal. Review the instructions for operating the machine on slopes in the Operator’s Manual as well as the conditions in which you would operate the machine to determine whether you can operate the machine in those conditions on that day and at that site.
Hour Meter Product Overview The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance (Figure 6). Fuel Gauge The fuel gauge is located with the hour meter, and the bars light up when the ignition switch is in the ON position (Figure 6). The indicator light appears when the fuel level is low (approximately 1 gallon remaining in the fuel tank).
Blade-Control Switch (Power Takeoff) Specifications The blade-control switch (PTO) engages and disengages power to the mower blades (Figure 5). change without notice. Note: Specifications and design are subject to Width: Ignition Switch 52-inch Deck 60-inch Deck 72-inch Deck Without Deck Use this switch to start the mower engine. It has 3 positions: START , RUN, and OFF. 116 cm (46 inches) 134.6 cm (53.0 inches) 150.1 cm (59.1 inches) Deflector Up 146 cm (58 inches) 156.8 cm (61.
Operation containers on the ground, away from your vehicle before filling. • Remove the equipment from the truck or trailer Note: Determine the left and right sides of the and refuel it while it is on the ground. If this is not possible, then refuel from a portable container rather than a fuel-dispenser nozzle. machine from the normal operating position. Before Operation • Do not operate the machine without the entire exhaust system in place and in proper working condition.
Using Stabilizer/Conditioner Use a fuel stabilizer/conditioner in the machine to provide the following benefits: • Keeps fuel fresh during storage of 90 days or less (drain the fuel tank when storing the machine for more than 90 days) • Cleans the engine while it runs • Eliminates gum-like varnish buildup in the fuel system, which causes hard starting Important: Do not use fuel additives containing methanol or ethanol. Add the correct amount of fuel stabilizer/conditioner to the fuel.
Using the Rollover Protection System (ROPS) WARNING To avoid injury or death from rollover: keep the roll bar in the fully raised locked position and use the seat belt. Ensure that the seat is secured to the machine. WARNING There is no rollover protection when the roll bar is in the down position. • Lower the roll bar only when absolutely necessary. • Do not wear the seat belt when the roll bar is in the down position. • Drive slowly and carefully. • Raise the roll bar as soon as clearance permits.
Think Safety First CAUTION This machine produces sound levels in excess of 85 dBA at the operator’s ear and can cause hearing loss through extended periods of exposure. Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. DANGER Wear hearing protection when operating this machine. Operating the machine on wet grass or steep slopes can cause sliding and loss of control.
to the NEUTRAL-LOCK position. Try starting the engine; the engine should not start. Positioning the Seat The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable. To adjust the seat, move the lever sideways to unlock the seat (Figure 12). g009181 Figure 11 1.
Changing the Seat Suspension During Operation During Operation Safety The seat adjusts to provide a smooth and comfortable ride. Position the seat where you are most comfortable. General Safety • The owner/operator can prevent and is responsible To adjust, turn the knob in front either direction to provide the best comfort (Figure 14). • • • • g019768 • Figure 14 1. Seat-suspension knob • • • • • • • • • • • 19 for accidents that may cause personal injury or property damage.
Slope Safety • Before leaving the operating position (including to empty the catchers or to unclog the chute), do the following: • Establish your own procedures and rules for operating on slopes. These procedures must include surveying the site to determine which slopes are safe for machine operation. Always use common sense and good judgment when performing this survey. – Stop the machine on level ground. – Disengage the power take-off and lower the attachments. – Engage the parking brake.
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) WARNING Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.
Starting the Engine 1. Raise the roll bar up and lock it into place, sit on the seat, and fasten the seat belt. 2. Move the motion controls to the NEUTRAL-LOCK position. 3. Engage the parking brake; refer to Engaging the Parking Brake (page 21). 4. Move the blade-control switch (PTO) to the OFF position (Figure 21). 5. Move the throttle lever midway between the SLOW and FAST positions. g008946 Figure 19 Operating the Ignition Switch 1. Turn the ignition key to the START position (Figure 20).
g008947 Figure 22 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 engage the parking brake when leaving the machine unattended, even if just for a few minutes. Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch to the OFF position.
Using the Motion-Control Levers CAUTION The machine can spin very rapidly. You may lose control of machine and cause personal injury or damage to the machine. • Use caution when making turns. • Slow the machine down before making sharp turns. Driving Forward Note: The engine shuts off when you move the traction-control with the parking brake engaged. To stop the machine, pull the motion-control levers to the NEUTRAL position. 1.
Driving Backward Using the Side Discharge 1. Move the levers to the center, unlocked position. 2. To go backward, slowly pull the motion-control levers rearward (Figure 26). 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.
Adjusting the Height of Cut Adjusting the Height-of-Cut Pin Using the Transport Lock 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. The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and a UNLOCK position for the transport position (Figure 27). 1. Move the transport lock to the lock position. 2.
Adjusting the Anti-Scalp Rollers Whenever you change the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. g000944 Figure 31 Adjust the anti-scalp rollers as shown in Figure 29, Figure 30, and Figure 31. 1.
Position B Use this position when bagging. Always align it with the blower opening. g027727 Figure 32 Positioning the Flow Baffle The following figures are only recommendations for use. Adjustments vary by grass type, moisture content, and the height of the grass. g005833 Figure 34 Note: If the engine power draws down and the mower ground speed is the same, open up the baffle. Position C Position A This is the full open position.
Operating Tips drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged or you can disengage the mower deck while moving forward. Using the Fast Throttle Setting For best mowing and maximum air circulation, operate the engine at the FAST position. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower in uncut grass.
Using the Drive-Wheel-Release Valves After Operation After Operation Safety General Safety WARNING • Clean grass and debris from the cutting units, • • • • • • Hands may become entangled in the rotating drive components below the engine deck, which could result in serious injury. mufflers, and engine compartment to help prevent fires. Clean up oil or fuel spills. Shut off the fuel before storing or transporting the machine.
Transporting the Machine Use a heavy-duty trailer or truck to transport the machine. 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, your family, pets, or bystanders avoid injury.
Loading the Machine Use extreme caution when loading or unloading machines onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back the machine up the ramp and drive it forward down the ramp (Figure 39). g028043 Figure 39 1. Back the machine up the ramp. 2. Drive the machine forward down the ramp. Important: Do not use narrow individual ramps for each side of the machine.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Change the engine oil. After the first 100 hours • Check the wheel lug-nut torque. • Check the wheel-hub slotted-nut torque. • Check the parking brake adjustment. After the first 250 hours • Change the hydraulic filters and hydraulic fluid when using any type of fluid. Before each use or daily • • • • • • • • Check the safety system. Check the engine-oil level.
CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Pre-Maintenance Procedures • To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.
Lubrication Grease more frequently when operating conditions are extremely dusty or sandy. Grease Type: No. 2 lithium or molybdenum grease 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Clean the grease fittings with a rag.
g009029 Figure 43 g009030 Figure 45 5. For all other machines, grease the mower deck idler-pulley pivot until grease comes out the bottom (Figure 44). 7. Remove the dust cap and adjust the caster pivots. Note: Keep the dust cap off until greasing is complete. Refer to Adjusting the Caster-Pivot Bearing (page 51). 8. Remove the hex plug. 9. Thread a grease fitting into the hole. 10. Pump grease into the fitting until it oozes out around the top bearing. 11.
Lubricating the Caster-Wheel Hubs 12. 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 13. Insert the second bearing and new seal into the wheel. 14. Apply a thread-locking adhesive to the second spacer nut, and thread it onto the axle with the wrench flats facing outward. 15. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen, then torque to 2 to 3 N∙m (20 to 25 in-lb). 1.
Engine Maintenance WARNING Contact with hot surfaces may cause personal injury. Keep your hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces. Engine Safety g012996 Figure 48 Shut off the engine before checking the oil or adding oil to the crankcase. Servicing the Air Cleaner 1. Air-inlet cover 3. Air-cleaner body 2. Air-inlet screen 4. Latch 6.
Installing the Filters Important: To prevent engine damage, always operate the engine with both air filters and the cover installed. 1. If installing new filters, check each filter for shipping damage. Note: Do not use a damaged filter. 2. If the inner filter is being replaced, carefully slide it into the filter body (Figure 49). 3. Carefully slide the primary filter over the inner filter (Figure 49). Note: Ensure that the primary filter is fully seated by pushing on the outer rim while installing it.
Servicing the Engine Oil Oil Type: Detergent oil (API service SJ or higher) Oil Capacity: with a filter change—1.65 L (56 oz); without a filter change—1.50 L (51 oz) Viscosity: See the table below. g008804 g012991 Figure 50 Note: Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F). Note: Synthetic oils provide better starting in extreme cold below -23°C (-10°F).
Changing the Engine Oil 5. Service Interval: After the first 8 hours Every 100 hours (more often in dirty or dusty conditions). Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 53). Note: Dispose of the used oil at a recycling center. 1. Start the engine and let it run for 5 minutes. Note: This warms the oil so that it drains better. 2. 3. 4.
Changing the Engine-Oil Filter Servicing the Spark Plug Service Interval: Every 200 hours Service Interval: Every 200 hours—Check, clean and regap the spark plug. 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 41). 2. Change the engine-oil filter (Figure 54). Ensure that the air gap between the center and side electrodes is correct before installing the spark plug.
5. Install the left hydraulic-unit shroud (Figure 55). Checking the Spark Plug Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable. g009922 If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means that the air cleaner is dirty. Set the gap to 0.76 mm (0.030 inches). g027479 Figure 57 Installing the Spark Plug Tighten the spark plug(s) to 24.4 to 29.
Checking the Spark Arrester Fuel System Maintenance For Models with a Spark Arrester WARNING Service Interval: Every 50 hours Fuel-system components are under high pressure. The use of improper components can result in system failure, gasoline leakage, and possible explosion. WARNING Hot exhaust system components may ignite fuel vapors even after you shut off the engine. Hot particles exhausted during engine operation may ignite flammable materials.
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. g008963 Figure 59 1. Fuel filter 2. Hose clamp WARNING 3. Fuel line 5.
Removing the Battery Installing the Battery Note: Position the battery in the tray with the terminal posts opposite from the hydraulic tank (Figure 60). WARNING Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.
Jump-Starting the Machine 1. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight. CAUTION Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure. Do not attempt to jump-start the machine with loose or corroded battery terminals, or damage to the engine or EFI may occur. g000960 Figure 62 1. Positive battery post 3. Red (+) charger lead 2. Negative battery post 4.
machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only. 3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 64. g008804 g013117 g012785 Figure 65 Figure 64 1. Positive (+) cable on discharged battery 5. Booster battery 2. Positive (+) cable on booster battery 6. Discharged battery 3.
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 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, 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 fast and slow. 4. Move both motion-control levers all the way forward until they both hit the stops in the T-slot. 5. Check which way the machine tracks.
g001297 Figure 70 1. Spring washers g027341 3. Dust cap 2. Lock nut Figure 69 1. Slotted nut Using the Clutch Shim Adjusting the Caster-Pivot Bearing Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, the shim can be removed to extend the clutch life. Service Interval: Every 500 hours/Yearly (whichever comes first) 1.
Removing the Clutch Shim 1. 2. B. Shut off the engine, wait for all moving parts to stop, remove the key, engage the parking brake, and allow the machine to cool completely before starting these instructions. Using needle-nose pliers, or by hand, hold the tab and remove the shim (Figure 74). Note: Do not discard the shim until proper clutch function has been confirmed. Using an air compressor, blow out any debris from under the brake pole and around the brake spacers (Figure 72).
Cooling System Maintenance Cleaning the Engine Screen and Engine-Oil Cooler Service Interval: Before each use or daily g010873 Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 77). Figure 76 1. Feeler gauge • If the gap is less than 0.25 mm (0.01 inch), then install the shim; refer to Troubleshooting (page 71). • If the gap is sufficient, proceed to the safety check in step F. F. g008804 Perform the following safety check: i. Sit on the seat and start the engine. ii.
Checking and Cleaning the Hydraulic-Unit Shrouds Service Interval: Before each use or daily 1. Disengage the blade-control switch (PTO) and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3. Move the seat forward. 4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 79). 5. Position the seat. g004218 Figure 78 1. Engine guard 4. Fan housing 2. Engine air-intake screen 5.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 100 hours Every 500 hours thereafter Note: This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced. 1. Drive the machine onto a level surface. 2. Disengage the blade-control switch (PTO), move the motion control levers to the NEUTRAL-LOCK position, and engage the parking brake. 3. Shut off the engine, wait for all moving parts to stop, and remove the key. 1.
Belt Maintenance Inspecting the Belts Service Interval: Every 50 hours Check the belts for squealing when the belt is rotating; blades slipping when cutting grass; frayed belt edges; burn marks; and cracks, which are signs of a worn mower belt. Replace the mower belt if any of these conditions occur. Replacing the Mower Belt 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2.
g027730 Figure 83 g009039 1. Position the belt cover 3. Ensure that the tab is under the metal catch Figure 84 2. Slide the belt cover under the side catches 1. Idler pulley 5. Left hydraulic-pump pulley 2. Clutch pulley 6. Square hole in the idler arm 7. Idler spring 3. Pump-drive belt 4. Right hydraulic-pump pulley Replacing the Hydraulic Pump-Drive Belt 5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 84). 6.
Controls System Maintenance Adjusting the Control-Handle Position There are 2 height positions for the control levers—high and low. Remove the bolts to adjust the height for the operator. 1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and engage the parking brake. 2. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 3.
4. Note: The wheels must stop turning or slightly Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat. creep in reverse. 11. Shut off the machine, remove the jumper wire from the wire harness, and plug the connector into the seat switch. Note: The switch is a part of the seat assembly. 5. Temporarily install a jumper wire across the terminals in the connector of the main wire harness. 12. Remove the jack stands. 13.
Adjusting the Motion-Control Neutral-Lock Pivot Hydraulic System Maintenance Hydraulic System Safety You can adjust the flanged nut to obtain the desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 89 for adjustment options. 1. Loosen the jam nut. 2. Tighten or loosen the flanged nut to the desired feel. • Ensure that all hydraulic-fluid hoses and • • For more resistance, tighten the flanged nut. • • • For less resistance, loosen the flanged nut 3.
8. Wipe the dipstick off and thread the dipstick into the reservoir. 9. Remove the dipstick and look at the end (Figure 90). WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done. Important: Do not overfill the hydraulic units with oil as damage may occur.
Replacing the Hydraulic Fluid and Filters Service Interval: After the first 250 hours—Change the hydraulic filters and hydraulic fluid when using any type of fluid. Every 250 hours—Change the hydraulic filters and hydraulic fluid when using Mobil® 1 fluid (more often in dirty or dusty conditions). Every 500 hours—Change the hydraulic filters and hydraulic fluid when using Toro® HYPR-OIL™ 500 hydraulic fluid (more often in dirty or dusty conditions). To replace the hydraulic fluid, 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 engage the parking brake. 3. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. 4. Check tire pressure of the drive tires. 5.
g009196 Figure 94 1. 7.6 cm (3 inch) at position A is correct 2. 8.3 cm (3-1/4 inch) at position B is correct 3. Measure here from the blade tip to the hard surface 4. Measure at position A and B on both sides g027344 10. Figure 95 Fine-tune the adjustment nut on the front deck lift assembly by turning it (Figure 95). Note: To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise. 1. Adjustment nut 3. Rear deck adjustment 2. Jam nut 4.
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, you may want to keep extra blades on hand.
Note: If this dimension exceeds 3 mm (1/8 inch), the blade is bent and must be replaced. WARNING A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders. • Always replace a bent or damaged blade with a new blade. g006530 Figure 98 1. Cutting edge 3. Wear/slot forming 2. Curved area 4. Crack • Do not file or create sharp notches in the edges or surfaces of the blade. Removing the Blades Checking for Bent Blades 1.
Sharpening the Blades 1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 101). Note: Maintain the original angle. Note: The blade retains its balance if the same amount of material is removed from both cutting edges. g000552 Figure 101 1. Sharpen at original angle. g004536 2. Figure 103 Check the balance of the blade by putting it on a blade balancer (Figure 102). Note: If the blade stays in a horizontal position, 1. Sail area of the blade 3. Spring disk 2. Blade 4.
g010252 Figure 105 5000 Series Machines 1. Right stabilizer 2. Deck strut (right side shown) 3. Remove the shoulder bolt and nut. 4. Remove the shoulder bolt and nut. g009038 Figure 104 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 4. Ratchet 7. Remove and retain the hardware on both sides of the deck as shown in Figure 105 or Figure 106. g009197 Figure 106 6000 Series Machines 1.
9. Cleaning Slide the deck out to the right side of the machine. Cleaning under the Mower Replacing the Grass Deflector 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.
Storage Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel and used at all times. Cleaning and Storage 1. 2. Disengage the power takeoff (blade-control switch (PTO), engage the parking brake, and turn the ignition key to the OFF position. Remove the key. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine and hydraulic system. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing.
Troubleshooting Problem The malfunction-indicator light (MIL) comes on. Possible Cause 1. The engine is too hot. 1. Shut off the engine and let it cool. 2. There is old fuel in the fuel tank. 3. The fuel-shutoff valve is not open completely. 4. The air cleaner is dirty. 2. Use new fuel. 3. Open the fuel-shutoff valve. 5. The battery is not charged. 6. Incorrect fuel filters are being used or the fuel filters are dirty. 7.
Problem The engine loses power. The engine overheats. The mower pulls to the left or right (with levers fully forward) The machine does not drive. The machine vibrates abnormally. The machine produces an uneven cutting height. Possible Cause 1. The engine load is excessive. 1. Reduce the ground speed. 2. The air cleaner is dirty. 3. The oil level in the crankcase is low. 4. The cooling fins and the air passages above the engine are plugged. 5. The vent hole in the fuel cap is plugged. 6.
Problem The clutch does not engage. Possible Cause Corrective Action 1. The fuse is blown. 1. Replace the fuse. Check the coil resistance, battery charge, charging system, and wiring connections, and replace components if necessary. 2. There is low voltage supply at the clutch. 2. Check the coil resistance, battery charge, charging system, and wiring connections and replace parts if necessary. 3. Replace the clutch. 4. Repair or replace the clutch lead wire or electrical system.
GND BK BK + - A C FUEL SENDER S B BU PK (PTO SWITCH) SW2 PK PK 2 3 BN BN BN V 4 5 BK BK U2 BK F4 PK 7 4 9 HOUR METER 7 W PK 12 OR 10 T SW6 (BRAKE) GND 15A 6 2 3 Y 11 LTGR SW4 (NEUT_L) BN 8 B PTO CLUTCH TVS DIODE BK A BN F3 SW5 (NEUT_R) PTO 1 PK FUEL_SOLENOID NEUTRAL 8 SEAT OR BRAKE 5 8 4 7 10A KEY_A 1 GN SW7 (SEAT) BN PK OR GY R OR R GY PK PK GY V SW1 (IGNITION) 2 5 1 3 B I S R 5 GN 2 OPTIONAL ACCESSORIES FUEL GROUND B+ KEY_S 74 MAGNETO
Notes:
The Toro Warranty Landscape Contractor Equipment (LCE) A Limited Warranty (see warranty periods below) Riding Product Conditions and Products Covered 3. If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at: The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the Toro Products listed below if defective in materials or workmanship.
