Z Master® 8000 Series Riding Mower

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

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.

1. Park the machine on a level surface, disengage the 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 bolts attached to the rubber guard (Figure 8).

   

   Figure 8

   1. Bolts
   2. Rubber guard

4. Fold the guard forward.

5. Loosen the bolts and remove the metal guards shown in Figure 9.

   

   Figure 9

   1. Guard attached to the mower deck
   2. Loosen the bolts
   3. Metal guards

6. Release the mower deck locking pins on each side (Figure 10).

   

   Figure 10

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

7. Using the deck-lift handle, lift the deck and latch it in the raised position (latch is located at front center of seat) as shown in Figure 11.

   

   Figure 11

   1. Secure the mower deck in the raised position by securing 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 11).

2. Install the metal guards and bolts as shown in Figure 9.

3. Install the rubber guard with the bolts (Figure 8).

4. Push the deck locking pins inward and rotate them forward to securely lock the mower deck in the lowered position (Figure 10).

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. Park the machine on a level surface, disengage the 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 bolts attached to the rubber guard (Figure 12).

4. Fold the guard forward.

   

   Figure 12

   1. Bolts
   2. Rubber guard

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

   

   Figure 13

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

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

7. Remove the bolt and washer at the front of each FRS baffle (Figure 14).

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

   

   Figure 14

   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 rubber guard using the attached bolts.

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.

Figure 18

Disengaging the Parking Brake

Figure 19

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

Engaging the PTO-Engagement Lever

Figure 20

Disengaging the PTO-Engagement Lever

Figure 21

You can move the throttle control between FAST and SLOW positions (Figure 22).

Always use the FAST position when engaging the PTO.

Figure 22

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

2. Engage the parking brake; refer to Engaging the Parking Brake.

3. Move the PTO-engagement lever to the OFF position (Figure 23).

4. Move the throttle lever midway between the SLOW and FAST positions.

5. Move the choke control to the CLOSED/ON position.

   

   Figure 23

6. Turn the key to the START position (Figure 23). When the engine starts, release the key.

   Important: Do not engage 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 the first time after adding fuel to an empty fuel system.

7. If the choke is in the CLOSED/ON position, gradually return choke to the OPEN/OFF position as the engine warms up.

1. Disengage the PTO.

2. Move the speed-control lever to the NEUTRAL position.

3. Engage the parking brake.

4. Place the throttle in the middle position.

5. Let the engine idle for 15 seconds, then turn the key switch to the OFF position and remove the key.

Figure 24

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

To unlatch the seat, remove the bolt and the pin on the left side of the seat (Figure 25).

Figure 25

1. Bolt and pin

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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. 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 26

   1. Cotter pin
   2. Mower-deck handle

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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. Lift the rear door up and allow it to rest on top of the 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 27).

Pull the screen toward 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 27

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. 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.

Selecting a Trailer

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 28).

• Use only a full-width ramp; do not use individual ramps for each side of the machine.

• Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.

• Ensure that the length of the ramp is at least 4 times as long as the height of the trailer or truck bed to the ground. This ensures that the ramp angle does not exceed 15 degrees on flat ground.

Figure 28

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15 degrees
4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5. H=height of the trailer or truck bed to the ground
6. Trailer

Grease Type: No. 2 lithium or molybdenum grease

1. Park the machine on a level surface, disengage the 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. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s).

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

5. Wipe up any excess grease.

   

   Figure 30

   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.

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.

Type: Champion^® RC12YC or equivalent

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plug

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.

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.

Set the gap to 0.76 mm (0.03 inch).

Figure 44

Installing the Spark Plug

Figure 45

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

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. Allow the machine to cool down.

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

5. Replace the fuel filter (Figure 46).

   Note: Ensure that the markings on the filter follow the fuel flow direction.

   

   Figure 46

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 and services any components of the fuel system.

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 49).

Figure 49

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

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 may occur.

   Danger

   Jump-starting a weak battery that is cracked or frozen or has a low electrolyte level or an open/shorted battery cell can cause an explosion, resulting in serious personal injury.

   Do not jump-start a weak battery if these conditions exist.

2. Make sure that the booster battery is a good and fully charged lead-acid battery at 12.6 V or greater.

   Note: Use properly sized jumper cables with short lengths to reduce voltage drop between systems. Make sure that the cables are color coded or labeled for the correct polarity.

   Caution

   Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the machine.

   Be certain of battery-terminal polarity and jumper-cable polarity when hooking up the batteries.

   Warning

   Batteries contain acid and produce explosive gases.

   • Shield your eyes and face from the batteries at all times.

   • Do not lean over the batteries.

   Note: Ensure that the vent caps are tight and level. Place a damp cloth, if available, over any vent caps on both batteries. Also ensure that the 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 50.

   

   Figure 50

   1. Positive (+) cable on discharged battery
   2. Positive (+) cable on booster battery
   3. Negative (–) cable on the booster battery
   4. Negative (–) cable on the engine block
   5. Booster battery
   6. Discharged battery
   7. Engine block

4. Connect the other end of the positive cable to the positive terminal of the booster battery.

5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6. Make the final connection on the engine block of the stalled machine (not to the negative battery post), away from the battery, and stand back (Figure 51).

   

   Figure 51

   1. Engine block (under the hood)
   2. Negative (–) cable

7. Start the machine and remove the cables in the reverse order of connection (disconnect the negative cable from the engine block first).

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.

2. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. Tilt the seat forward to gain access to the tracking knob.

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

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

7. Check and ensure that the machine does not creep when in neutral with the parking brakes disengaged (Figure 52).

   

   Figure 52

   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 53

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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 dust cap from the caster and tighten the locknut until the spring washers are flat, then back off 1/4 turn to properly set the pre-load on the bearings (Figure 54 and Figure 55).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 54 and Figure 55.

4. Install the dust cap.

   

   Figure 54

   Front Caster

   1. Spring washers
   2. Locknut
   3. Dust cap
   

   Figure 55

   Rear Caster

   1. Spring washers

Remove any buildup of grass, dirt, or other debris from the oil cooler and 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. Release the parking brake.

4. Tilt the seat forward.

5. Check and ensure that 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 56

   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 57

   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 58).

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

   

   Figure 58

   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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. 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 the belts are replaced.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. 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 59).

7. Remove the belts.

8. Route the new belts onto the pulleys as shown in Figure 59.

   

   Figure 59

   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. 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 60.

    

    Figure 60

    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

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

14. Engage the PTO lever and check the alignment.

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

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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 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 61).

   

   Figure 61

   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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the 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. With the engine off, engage the PTO lever.

4. Adjust the belt guides as shown in Figure 62.

Figure 62

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 center the belts in the guide.
5. 6 mm (1/4 inch)
6. 8 mm (5/16 inch)

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. 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 63

        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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. Adjust the pivot nut, which is located at the end of the motion-control shaft in front of the right console (Figure 64).

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

   

   Figure 64

   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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 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 seat safety switch 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 fluid 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 65).

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 65).

    

    Figure 65

    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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 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 66).

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

   

   Figure 66

   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 Pump-Drive Pulley.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 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 66).

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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. Locate the brake spring and thread the 2 jam nuts out to the end of the brake-spring rod (Figure 67).

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

   

   Figure 67

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

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 6 door hinge nuts (Figure 68).

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 68).

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 68

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 operating 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 69).

   

   Figure 69

   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 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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 mower deck up and latch with deck-locking pins. Refer to Raising the Mower Deck into Service Position.

4. Remove the hairpin cotters and washers at the top of the deck-lift-assist spring on each side of the machine (Figure 77).

   

   Figure 77

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

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

6. 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 when you remove the springs from the anchors. Lower the mower deck carefully.

7. Remove the lynch pins at the front of the push arms on both sides of the machine (Figure 78).

   

   Figure 78

   1. Push arm
   2. Lynch pin
   3. Push-arm tube

8. Loosen the bolts attached to the rubber guard (Figure 79).

   

   Figure 79

   1. Bolts
   2. Rubber guard

9. Unlatch the seat and disconnect the drive shaft using the quick coupler at the jackshaft (Figure 80). Refer to Unlatching the Seat

   

   Figure 80

   1. Jackshaft
   2. Drive shaft

10. 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. 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.

4. Unlatch the seat and tilt the seat forward.

5. Install the drive shaft onto the jackshaft (Figure 80).

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

7. Secure the push arms with the lynch pins on the left and right sides of the machine (Figure 78).

8. Align the upper portion of the rubber guard and secure it with the attached bolts (Figure 79).

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

10. Install the springs onto the spring anchor pins under the left and right consoles and secure it with a washer and hairpin cotter (Figure 77).

11. 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 operating 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 81).

   

   Figure 81

   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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. Lift the mower deck and secure it in the raised position. Refer to Raising the Mower Deck into 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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, 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. 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.