Z Master® 8000 Series Riding Mower

• 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. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.

• Do not add oil to gasoline.

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.

  Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Note: Do not fill the fuel tank completely full. Fill the fuel tank to the bottom of the filler neck. The empty space in the tank allows the fuel to expand.

1. Park the machine on level ground.

2. Shut the engine off and engage the parking brake.

3. Clean around the fuel-tank cap and remove it.

4. Fill the fuel tank to the bottom of the filler neck.

   Note: Ensure that there is empty space in the tank to allow the gasoline to expand; refer to (Figure 4).

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine-Oil Level.

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.

Please read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury.

Figure 7

1. Safe Zone—use the machine here on slopes less than 15 degrees or flat areas.
2. Danger Zone—use a walk-behind mower and/or a hand trimmer on slopes greater than 15 degrees, near drop-offs and water.
3. Water

Use protective equipment for your eyes, ears, hands, feet, and head.

Figure 8

1. Wear eye protection.
2. Wear hearing protection.

1. Shut off the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake.

   Warning

   Incorrectly raising or lowering a mower deck can be dangerous. A dropped mower deck can result in a serious injury or property damage.

   • Always raise and lower the mower deck on flat, dry ground, free of any obstructions.

   • Firmly grasp the mower-deck-lift handle and lower it in a slow, controlled manner.

   • Always make sure the mower deck is securely latched in the up or down position.

2. Release the mower-deck locking pins on each side (Figure 9).

   

   Figure 9

   1. Deck-lift handle
   2. Rotate the pin toward the rear and pull outward to unlock.
   3. Push the pin in and rotate it toward the front to lock.

3. Using the deck-lift handle, lift the deck up and latch it in the Up position (Figure 10).

   Note: The latch is located at the front center of the seat.

   

   Figure 10

   1. Secure the mower-deck latch onto the hook.
   2. Hook
   3. Deck-lift handle

1. While firmly holding onto the deck-lift handle, unhook the mower-deck latch from the machine and slowly lower the mower deck to the ground (Figure 10).

2. Push the deck-locking pins inward and rotate them forward to securely lock the mower deck in the lowered position (Figure 9).

The fill reduction system has been designed to allow you to reduce the amount of clippings collected by varying degrees.

The advantages include less frequent emptying of the hopper and the return of nutrients to the soil.

The following are possible configurations:

• Baffles open with standard blades—maximum collection

• Baffles closed with standard blades—partial mulching

• Baffles closed with mulch blades—intermediate mulching

• Mulch plug installed with mulch blades—complete mulching (requires mulch kit)

Adjust the FRS baffles as follows:

1. Shut off the engine, wait for all moving parts to stop, and remove key.

2. Engage the parking brake.

3. Remove the hairpin cotters and clevis pins from both sides of the PTO guard (Figure 11).

4. Fold the guard forward.

   

   Figure 11

   1. Hairpin cotter and clevis pin

5. Loosen the locknuts on the rear studs of the FRS baffles.

   

   Figure 12

   1. PTO guard removed for clarity
   2. Loosen the locknuts.

6. Raise the mower deck; refer to Raising the Mower Deck into the Service Position.

7. Remove the bolt and washer at the front of each FRS baffle (Figure 13).

8. Rotate the baffles into the desired position and install the bolt and washer.

   

   Figure 13

   1. Baffles—closed position
   2. Baffles—open position
   3. Bolt
   4. Washer
   5. Baffles

9. Lower the mower deck; refer to Lowering the Mower Deck to the Operating Position.

10. Slightly tighten the locknuts on the rear studs of the FRS baffles.

    Note: The locknuts on the rear studs may be left slightly loose if you anticipate adjusting the baffle frequently.

11. Install the PTO guard using the clevis pins and hairpin cotters removed in step 3.

You can move the throttle control between the FAST and SLOW positions (Figure 15).

Always use the middle position when turning on the mower deck and blower with the PTO-engagement lever.

Figure 15

1. Turn the ignition key to the START position (Figure 16).

   Note: When the engine starts, release the key.

   Important: Do not engage the starter for more than 5 seconds at a time. If the engine fails to start, wait 15 seconds between attempts. Failure to follow these instructions can burn out the starter motor.

   Note: You may need multiple attempts to start the engine when you start it the first time after the fuel system has been without fuel completely.

   

   Figure 16

2. Turn the ignition key to the STOP position to shut off the engine.

The PTO-engagement lever starts and stops the mower blades and blower.

Engaging the PTO-Engagement Lever

Figure 17

Disengaging the PTO-Engagement Lever

Figure 18

Always engage the parking brake when you stop the machine or leave it unattended.

Engaging the Parking Brake

Warning

The parking brake may not hold the machine parked on a slope and could cause personal injury or property damage.

Do not park on slopes unless the wheels are chocked or blocked.

Figure 19

Disengaging the Parking Brake

Figure 20

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Always operate in the full throttle position when mowing.

The cutting height of the mower deck is adjusted from 2.5 to 10.2 cm (1 to 4 inches) in 6.3 mm (1/4 inch) increments.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Using the mower-deck handle, raise the mower deck, and move the cotter pins to the desired height-of-cut position. Repeat for the opposite side.

   

   Figure 23

   1. Cotter pin
   2. Mower-deck handle

1. Pull the speed-control lever back to the NEUTRAL position, disengage the PTO-engagement lever, and turn the ignition key to the OFF position.

2. Engage the parking brake when you leave the machine; refer to Engaging the Parking Brake.

3. Remove the key from the ignition switch.

A full hopper is indicated by a buzzer located behind the seat, in the hopper. Empty the hopper when the buzzer sounds to prevent clogging of the blower or the mower deck.

1. Disengage the PTO, move the speed-control lever to the NEUTRAL position, engage the parking brake, and dismount the machine.

2. Make sure that machine is on a dry level surface.

3. Lift the rear door up and allow it to rest on top of hopper.

4. Using the handles at the lower front of the hopper, raise the hopper to dump the contents.

5. Lower the hopper and close the hopper door.

Remove the screen by firmly lifting the screen handles (Figure 24).

Pull the screen towards the back to remove it. As needed, gently tap the screen to remove debris.

Note: Excessive buildup on the screen can cause the blower to plug.

Note: In conditions where the screen clogs quickly, you can turn and install the front removable screen panel under the primary screen to allow free air flow from the hopper.

Figure 24

1. Front removable screen can be rotated and stored for wet conditions.
2. Front removable screen
3. Primary screen
4. Handles

The drive-wheel release valves are located on the top, left, front corner of the hydrostatic pumps.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO lever, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Tilt the seat up to gain access to the pumps.

4. Rotate both release valves 1 turn counterclockwise to release the drive system.

   Note: This allows the hydraulic fluid to bypass the pump, enabling the wheels to turn.

5. Disengage the parking brake before pushing the machine.

   Note: Do not tow the machine.

6. Rotate the valves clockwise to run the machine.

   Note: Do not overtighten the valves.

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets, or bystanders avoid injury.

1. If using a trailer, connect it to the towing vehicle and connect the safety chains.

2. If applicable, connect the trailer brakes.

3. Load the machine onto the trailer or truck.

4. Shut off the engine, remove the key, set the brake, and close the fuel valve.

5. Securely fasten the machine to the trailer or truck with straps, chains, cable, or ropes down and outward from the machine.

Use extreme caution when loading or the unloading machine onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure.

Important: If a full-width ramp is not available, use enough individual ramps to simulate a full-width ramp.

Ensure that the ramp is long enough so that the angle with the ground does not exceed 15 degrees. A steeper angle may cause mower components to get caught as the machine moves from the ramp to the trailer or truck. Steeper angles may also cause the machine to tip or lose control. If you are loading the machine on or near a slope, position the trailer or truck so that it is on the down side of the slope and the ramp extends up the slope. This minimizes the ramp angle.

Important: Do not attempt to turn the machine while on the ramp, you may loose control and drive off the side.

Grease Type: No. 2 lithium or molybdenum grease

1. Disengage the PTO, stop the machine, shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

2. Clean the grease fittings with a rag. Scrape any paint off the front of the fitting(s).

3. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings.

4. Wipe up any excess grease.

   

   Figure 25

   1. Rear caster pivot
   2. PTO-belt idler arm
   3. Pump-belt idler arm
   4. Rear caster hub
   5. Drive shaft
   6. Front caster wheel hub
   7. Deck flip-up pivot
   8. Push-arm tubes
   9. Front caster pivots

Note: Check the filters more frequently if the operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service class SJ or higher)

Oil Capacity: with a filter change, 1.8 L (61 fl oz); with no filter change, 1.6 L (54 fl oz)

Viscosity: See the table below.

Figure 30

Make sure that the air gap between the center and side electrodes is correct before installing the spark plugs. Use a spark-plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary.

Type: Champion^® RC12YC or equivalent

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plugs

Important: Replace the spark plugs when they have: a black coating, worn electrodes, an oily film, cracks or reuse is questionable.

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 inch).

Figure 35

Installing the Spark Plugs

Tighten the spark plugs to 24.4 to 29.8 N∙m (18 to 22 ft-lb).

Figure 36

1. Shut off the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake.

2. Wait for the muffler to cool.

3. If there are any breaks in the screen or welds, replace the arrester.

4. If the screen is plugged, remove the arrester and shake the loose particles out of the arrester and clean the screen with a wire brush (soak it in solvent if necessary). Install the arrester on the exhaust outlet.

The fuel filter is located near the engine on the front or rear side of the engine.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Wait for the machine to cool down.

4. Clamp the hose on the fuel tank side of the fuel filter.

5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 37).

   

   Figure 37

   1. Fuel filter
   2. Hose clamp
   3. Fuel line

6. Remove the filter from the fuel lines.

7. Install a new filter and move the hose clamps close to the filter (Figure 37).

8. Open the fuel-shutoff valve.

Note: Install the fuel-line hoses and secure them with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage.

Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank.

The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows check the component/circuit for a malfunction or short.

1. The fuses are located on right side behind the seat.

2. To replace the fuses, pull out on the fuse to remove it.

3. Install a new fuse.

Adjust all safety switches so that the plunger extends 4.8 mm to 6.4 mm (3/16 inch to 1/4 inch) from the switch body when the plunger is compressed (Figure 40).

Figure 40

1. 4.8 to 6.4 mm (3/16 to 1/4 inch)

Note: The tracking knob is located under the seat.

Note: Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position.

1. Run the machine at 3/4 speed for at least 5 minutes to bring hydraulic fluid up to operating temperature. Stop machine and wait for all moving parts to stop.

2. Engage the parking brake.

3. Tilt the seat forward to gain access to the tracking knob.

4. Rotate the knob toward the right to steer right and rotate it toward the left to steer left.

5. Adjust in 1/8 turn increments until the machine tracks straight.

6. Check and ensure that the machine does not creep when in neutral with the parking brakes disengaged (Figure 41).

   

   Figure 41

   1. Tracking knob

Maintain the air pressure in the rear tires at 103 kPa (15 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold, to get the most accurate pressure reading.

Note: The front tires are semi-pneumatic tires and does not require air pressure maintenance.

Figure 42

Note: Do not add any type of tire liner or foam fill material to the tires.

Check and torque the wheel-lug nuts to 122 to 129 N∙m (90 to 95 ft-lb).

Check and ensure that the torque of the slotted nut is 373 to 475 N∙m (275 to 350 ft-lb).

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the dust cap from the caster and tighten the locknut (Figure 43 and Figure 44).

4. Tighten the locknut until the spring washers are flat and then back off 1/4 turn to properly set the pre-load on the bearings (Figure 43 and Figure 44).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 43 and Figure 44.

5. Install the dust cap.

   

   Figure 43

   Front Caster

   1. Spring washers
   2. Locknut
   3. Dust cap
   

   Figure 44

   Rear Caster

   1. Spring washers

Remove any buildup of grass, dirt, or other debris from the oil cooler.

Before each use remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to the engine.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the fuel-tank mounting nuts and swing out the fuel tank.

4. Keep the oil cooler free of debris by cleaning the fins with a brush.

5. Swing the fuel tank in and secure it with the mounting nuts.

6. Back the mounting nuts off 1/2 turn to allow for tank expansion.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the air-intake screen and fan housing.

4. Clean the debris and grass from the engine parts.

5. Install air-intake screen and fan housing.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Raise the seat.

4. Clean the debris and grass from the hydraulic pumps.

5. Lower the seat.

Make sure that the brake is adjusted properly. Follow this procedure when you remove or replace a brake component.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Release the parking brake.

4. Tilt the seat forward.

5. Check and ensure there is no slack between the parking-brake handle and the linkage.

6. If an adjustment is necessary, remove the clevis pin and rotate the linkage counterclockwise to lengthen it or clockwise to shorten it.

   

   Figure 45

   1. Parking brake
   2. Rotate yoke
   3. Clevis pin
   4. Speed-control lever
   5. Steering levers

7. Measure the compressed spring length on both vertical spring assemblies.

   Note: The spring should measure between 6 to 7 cm (2.35 to 2.85 inches). If necessary, adjust the nut at the top of the vertical spring assembly to achieve this distance.

   

   Figure 46

   1. Parking brake
   2. Steering lever
   3. Speed-control lever
   4. Vertical spring assembly
   5. Nut
   6. 6 to 7 cm (2.35 to 2.85 inches)

8. Adjust the linkage length with the 2 nuts at the bottom of the vertical spring assembly (Figure 47).

   Note: The linkage should measure 22.7 to 23.3 cm (8.92 to 9.16 inches).

   

   Figure 47

   1. 22.7 to 23.3 cm (8.92 to 9.16 inches)
   2. Nuts

9. Engage and disengage the brakes to check for proper engagement and disengagement. Adjust if necessary.

   Note: When the brakes are disengaged, there should be little to no free play in the brake linkage with no dragging in the brakes.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Tilt the hopper up and check the pump and PTO drive belts for wear, cracking, or contamination.

   Note: The belts are spring tensioned and no adjustment is necessary unless you replace the belts.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. With the engine off, engage the PTO lever, then remove the hairpin cotter and clevis pin at the bottom of the PTO-brake band.

4. Rotate the brake band upward and out of the way of the belts keeping clear of the belt drive.

5. Disengage the PTO lever.

6. Loosen belt guides A and B (Figure 48).

7. Remove the belts.

8. Route the new belts onto the pulleys as shown in Figure 48.

   

   Figure 48

   1. Idler
   2. Belt guide B
   3. PTO belt
   4. Jackshaft
   5. Engine
   6. Belt guide A
   7. Blower

9. Engage the PTO lever.

10. Rotate the brake band down into the original position.

11. Install the clevis pin and hairpin cotter to secure the brake band.

12. Engage the PTO lever.

13. Loosen the jam nuts and adjust the linkage until the top of the idler arm is aligned with the bottom of the notch on the tension arm as shown in Figure 49.

    

    Figure 49

    1. Tension arm
    2. Loosen the jam nuts.
    3. When PTO is engaged, align top of idler arm with bottom of notch on tension arm, as shown.
    4. Idler arm

14. Tighten the jam nuts and disengage the PTO lever.

15. Engage the PTO lever and check the alignment.

16. Check and adjust the belt guides as stated in Adjusting the Belt Guides.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the PTO Belts; refer to Replacing the PTO Belts.

4. Pull the spring idler or remove the spring to relieve the tension of the pump-drive belt.

5. Remove the old belt.

6. Route the new belt onto the sheaves as shown in the decal located on the back of the left drive shield (Figure 50).

   

   Figure 50

   1. Pump-drive belt
   2. Pump
   3. Idler
   4. Pump
   5. Idler
   6. Engine

7. Install the PTO belts; refer to Replacing the PTO Belts.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. With the engine off, engage the PTO lever.

4. Adjust the belt guides as shown in Figure 51.

Figure 51

1. 3 mm (1/8 inch)
2. 11 mm (7/16 inch)
3. 3 mm (1/8 inch) clearance
4. Rotate the wireform guide to the center belts in the guide.
5. 6 mm (1/4 inch)
6. 8 mm (5/16 inch)

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Check the movement of the steering levers as follows:

   • If the levers move slightly forward up to 3 mm (1/8 inch) then no adjustment is necessary.

   • If the levers do not move, then proceed with the following steps:

     1. Flip the seat up or remove the seat-frame assembly (with the seat attached) to obtain a clear view of the steering-control shaft to complete this adjustment.

     2. Place the speed-control lever in the NEUTRAL position.

     3. Release the parking brake.

     4. Slightly adjust the length of the rod by loosening the jam nut and by rotating the rod.

        

        Figure 52

        1. Parking brake
        2. Nut
        3. Steering lever
        4. Speed-control lever
        5. Clevis pin and stop rod

     5. Engage the parking brake and check the steering levers.

     6. Repeat steps 3 through 5 until you achieve up to 3 mm (1/8 inch) movement.

     7. Install the seat frame assembly, if removed in step 1.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. To adjust the tension, adjust the pivot nut, which is located at the end of the motion-control shaft in front of the right console (Figure 53).

   Note: Set the tension high enough that the speed-control lever position is maintained during operation and loose enough to be moved comfortably.

   

   Figure 53

   1. Pivot nut
   2. Spring-disc washers
   3. Speed-control friction plate
   4. Friction disc
   5. Speed-control friction bracket
   6. Speed-control lever

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the electrical connection from the seat safety switch, located directly in front of the seat-switch assembly.

4. Raise the frame and place on jack stands so that drive wheels can rotate freely.

   Note: You must make the neutral adjustment with the drive wheels turning.

5. Temporarily install a jumper wire across the terminals in the connector of the wiring harness.

6. Start the engine.

7. Run the machine at least 5 minutes with the speed-control lever at full forward speed to bring the hydraulic system oil up to operating temperature.

8. Return the speed-control lever to the NEUTRAL position.

9. To obtain the NEUTRAL position, adjust the left and right pump-control-rod linkages that connect the steering control to the pump-control arms until the wheels stop or creep slightly in reverse (Figure 54).

10. Adjust the left pump linkage by rotating the tracking-adjustment knob.

11. Adjust the right pump linkage by using a wrench to turn the double nuts on the assembly (Figure 54).

    

    Figure 54

    1. Rotate the tracking knob on left side.
    2. Rotate the double nuts on right side.

12. Move the steering levers to the reverse position. While applying slight pressure to the levers, allow the steering levers to return to NEUTRAL.

    Note: The wheels must stop turning or slightly creep in reverse.

13. Shut off the engine and wait for all moving parts to stop.

14. Remove the jumper wire from the wire-harness connector and plug the connector into the seat switch.

15. Lower the machine from the jackstands.

Align the PTO-drive pulley for any of the following conditions:

• The blower has been removed or replaced.

• The engine mounting bolts have been loosened or the engine has been moved or replaced.

• The jackshaft mounting bolts have been loosened or the jackshaft has been moved or replaced.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Remove the fuel-tank mounting nuts and swing out the fuel tank.

4. Verify that the blower is installed and tightly secured.

5. Loosen the 4 engine mounting bolts.

6. Unhook the pump-belt tension spring.

7. Loosen the 4 jackshaft mounting bolts.

8. Measuring from the blower pulley as a baseline, move the engine and jackshaft until the rear surface of all 3 pulleys are aligned within 0.8 to 1.6 mm (1/32 inch to 1/16 inch) (Figure 55).

   Note: Use a straight edge to align all 3 surfaces.

   

   Figure 55

   1. Align the 3 pump-drive pulley surfaces shown with this pattern within 0.8 to 1.6 mm (1/32 inch to 1/16 inch).
   2. Align the 3 PTO-drive pulley surfaces shown with this pattern within 0.8 to 1.6 mm (1/32 inch to 1/16 inch).

9. Tighten the 4 engine mounting bolts and 4 jackshaft mounting bolts. Check the alignment after tightening.

10. Install the pump-belt tension spring.

11. Swing the fuel tank in and install the tank mounting nuts.

12. Align the pump-drive pulley; Aligning the Pump-Drive Pulley.

The pump-drive-pulley alignment is necessary for any of the following conditions:

• The engine mounting bolts have been loosened or the engine has been moved or replaced.

• The pump pulleys have been loosened, moved, or replaced.

• The PTO pulley has been aligned; refer to Aligning the PTO-Drive Pulley.

1. Shut off the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Loosen the set screws on both pump pulleys.

4. Using a straight edge, align each pump pulley with the engine pulley by sliding it along the pump shaft (Figure 55).

5. Tighten the pulley set screws and check the alignment.

Adjust the PTO brake spring only if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled.

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Locate the brake spring and thread the 2 jam nuts out to the end of the brake-spring rod (Figure 56).

4. Tighten the jam nuts together at end of the brake-spring rod.

   

   Figure 56

   1. Tighten the jam nuts here.
   2. PTO brake-spring assembly

1. Stop the machine and move the speed-control lever to the NEUTRAL position.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Loosen the 6 door hinge nuts (Figure 57).

4. Open the door and place a 3/8 inch (9.5 mm) rubber strip or 3/8 inch (9.5 mm) diameter hose between the hopper and the hopper door (Figure 57).

5. Close the door and push it tight against the hopper.

6. Tighten the hinge hardware.

7. Open the hopper door and remove the rubber strip.

Figure 57

1. Loosen the door hinge nuts—3 per side.
2. Place a piece of 9.5 mm (3/8 inch) rubber on this surface.

1. Slide the mower-deck locking pins in on both sides of the mower deck and rotate them to lock the mower deck in the operation position.

2. Loosen the jam nut and turn the stop screw clockwise until the locking pin is tight and cannot be rotated by hand (Figure 58).

   

   Figure 58

   1. Rotate the stop screw clockwise until the locking pin is tight, then back off 1/2 turn.
   2. Loosen the jam nut.

3. Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut.

4. Test the locking pin to make sure that it slides freely. Adjust it if necessary.

Hydraulic Fluid Type: Toro^® HYPR-OIL^™ 500 hydraulic oil or Mobil^® 1 15W-50.

Important: Use the fluid specified. Other fluids could cause system damage.

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.

Important: Do not transport this machine without an approved Toro front mount attachment.

1. Shut off the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake.

2. Raise the mower deck up and latch it with the deck-locking pins. Refer to Raising the Mower Deck into the Service Position.

3. Remove the hairpin cotters and washers at the top of the deck-lift-assist spring on each side of the machine (Figure 66).

   

   Figure 66

   1. Spring-anchor pin under console
   2. Secure springs with a washer and hairpin cotter.
   3. Slide spring onto spring-anchor pin.

4. Remove the spring from the spring anchor. Repeat for other side of the machine.

5. Unlatch the mower deck from the raised position and slowly lower the mower deck to ground; refer to Lowering the Mower Deck to the Operating Position.

   Note: The mower deck becomes heavier once you remove the springs from the anchors. Lower the mower deck carefully.

6. Remove the lynch pins at front of push arms on both sides of the machine (Figure 67).

   

   Figure 67

   1. Slide the push arm into the deck push-arm tube.
   2. Secure the push pin arm with lynch pin.

7. Remove the hairpin cotter and clevis pin from both sides of the PTO guard (Figure 68).

   

   Figure 68

   1. Secure the PTO guard with the clevis pin and hairpin cotter.

8. Raise the seat and disconnect the drive shaft using the quick coupler at the jackshaft (Figure 69).

   

   Figure 69

   1. Jackshaft
   2. Drive shaft

9. Pull the mower deck forward to remove it from the machine.

Important: Do not transport the machine without an approved Toro front mount attachment.

1. Shut off the engine, wait for all moving parts to stop and remove the key. Engage the parking brake.

2. Roll the mower deck up to the machine with the discharge tube down, making sure that the deck springs are located above the drive wheel and below the console on each side.

3. Raise the seat and install the drive shaft onto the jackshaft (Figure 69)

4. Align the mower-deck push-arm tubes to the machine push-arms and push the mower deck rearward.

5. Secure the push arms with the lynch pins on the left and right sides of the machine (Figure 67).

6. Align the upper portion of the rubber PTO guard to the tabs on the front of the console and secure with a clevis pin and hairpin cotter on each side (Figure 68).

7. Release the mower-deck locking pins on each side, raise the mower deck to the service position, and secure the deck latch onto hook. Refer to Raising the Mower Deck into the Service Position.

8. Install the springs onto the spring anchor pins under the left and right consoles and secure with a washer and hairpin cotter (Figure 66).

9. Unlatch the mower deck from the raised position, slowly lower the mower deck to ground, and lock the deck-locking pins on each side. Refer to Lowering the Mower Deck to the Operating Position.

1. Slide the mower-deck locking pins in on both sides and rotate to lock the deck in the operation position.

2. Loosen the jam nut and turn the stop screw clockwise until the locking pin is tight and cannot be rotated by hand (Figure 70).

   

   Figure 70

   1. Rotate the stop screw clockwise until locking pin is tight, then back off 1/2 turn.
   2. Loosen the jam nut

3. Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut.

4. Test the locking pin to make sure it slides freely. Adjust it if necessary.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Lift the mower deck and secure it in the raised position. Refer to Raising the Mower Deck into the Service Position.

4. Clean any grass buildup under the mower deck.

5. Lower the mower deck to the operating position. Refer to Lowering the Mower Deck to the Operating Position.

1. Shut off the engine, wait for all moving parts to stop, and remove the key. Engage the parking brake.

2. Clean off any oil, debris, or grass buildup on the machine, especially around the fuel tank, engine, and exhaust area.

Engine oil, batteries, hydraulic fluid, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.