Z Master® Commercial 3000 Series Riding Mower

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

• Do not run an engine in an enclosed area.

• Operate only in well-lit areas, keeping away from holes and hidden hazards.

• Ensure that all drives are in neutral and that the parking brake is engaged before starting engine. Start the engine only from the operator’s position.

• Make sure that you have good footing while using this machine, especially when backing up. Reduced footing could cause slipping.

• Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. Turf conditions can affect the stability of the machine. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and when changing directions on slopes.

• Do not raise the mower deck with the blades running.

• Do not operate the machine without the PTO shield or other guards securely in place. Be sure that all interlocks are attached, adjusted properly, and functioning properly.

• Do not operate with the discharge deflector raised, removed or altered, unless you are using a grass catcher.

• Do not change the engine governor setting or overspeed the engine.

• Stop the machine on level ground, disengage drives, engage the parking brake (if provided), shut off the engine before leaving the operator's position for any reason, including emptying the catchers or unclogging the chute.

• Stop the machine and inspect the blades after striking objects or if an abnormal vibration occurs. Make the necessary repairs before resuming operation.

• Keep your hands and feet away from the cutting unit.

• Look behind and down before backing up to ensure a clear path.

• Keep pets and bystanders away from an operating machine.

• Slow down and use caution when making turns and crossing roads and sidewalks. Stop the blades if you are not mowing.

• Be aware of the mower-discharge direction and do not point it at anyone.

• Do not operate the mower while ill, tired, or under the influence of alcohol or drugs.

• Use care when loading or unloading the machine into or from a trailer or truck.

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• To avoid personal injury or property damage, use extreme care in handling gasoline. Gasoline is extremely flammable and the vapors are explosive.

• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

• Use only an approved fuel container.

• Do not remove the fuel cap or add fuel with the engine running.

• Allow the engine to cool before fueling.

• Do not fuel the machine indoors.

• Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or on other appliances.

• Do not fill containers inside a vehicle, on a truck, or on a trailer bed with a plastic liner. Always place containers on the ground away from your vehicle before filling.

• Remove equipment from the truck or trailer and fuel it on the ground. If this is not possible, then add fuel with such equipment as a portable container rather than from a fuel-dispenser nozzle.

• Keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not use a nozzle lock-open device.

• If you spill fuel on clothing, change your clothing immediately.

• Do not overfill the fuel tank. Replace the fuel cap and tighten it securely.

• Disengage drives, set the parking brake, shut off the engine, and remove the key or disconnect spark-plug wire. Wait for all movement to stop before adjusting, cleaning, or repairing the machine.

• Park the machine on a level surface.

• Clean grass and debris from the cutting unit, drives, mufflers, and engine to help prevent fires.

• Clean up oil or fuel spills.

• Let the engine cool before storing the machine.

• Do not store fuel near flames or drain fuel indoors.

• Do not allow untrained personnel to service the machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect the battery or remove the spark-plug wire before making any repairs. Disconnect the negative terminal first and the positive terminal last. Connect the positive terminal first and negative last.

• Use care when checking the blades. Wrap the blade(s) or wear thickly padded gloves, and use caution when servicing them. Only replace blades; do not straighten or weld them.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• Use care when loading or unloading the machine into a trailer or a truck.

• Use a full-width ramp for loading machine into a trailer or a truck.

• Tie the machine down securely using straps, chains, cable, or ropes. Both front and rear straps should be directed down and outward from the machine.

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

• 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, and follow the directions of the manufacturer.

Note: Fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. 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 gasoline to expand.

1. Park the machine on level ground.

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

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

4. Fill the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.

   Note: Ensure that there is empty space in the tank to allow the gasoline to expand.

   

   Figure 7

Note: Engaging the blade-control switch (PTO) with the throttle position at half or less causes excessive wear to the drive belts.

Figure 14

1. Raise the ROPS up and lock into place, sit on the seat, and fasten the seat belt.

2. Move the motion controls to the NEUTRAL-LOCK position.

3. Set the parking brake; refer to Setting the Parking Brake.

4. Move the blade-control switch (PTO) to the OFF position (Figure 20).

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

   

   Figure 20

6. Turn the key in the ignition switch to the START position (Figure 21). When the engines starts, release the key.

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

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

Figure 21

Let the engine idle at slow throttle (turtle) for 60 seconds before turning the ignition switch to the OFF position.

Figure 22

Important: Make sure that the fuel shutoff valve is closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge.

The safety-interlock system is designed to prevent the engine from starting unless:

• The parking brake is engaged.

• The blade-control switch (PTO) is disengaged.

• The motion-control levers are in the NEUTRAL-LOCK position.

The safety-interlock system also is designed to shut off the engine when you move the traction controls from the locked position with the parking brake engaged or if you rise from the seat when the PTO is engaged.

The hour meter has symbols to notify the user when the interlock component is in the correct position. When the component is in the correct position, a triangle lights up in the corresponding square.

Figure 23

1. Triangles light up when the interlock components are in the correct position

Test the safety-interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

1. Sitting on the seat, engage the parking brake and move the blade-control switch (PTO) to the ON position. Try starting the engine; the engine should not crank.

2. Sitting on the seat, engage the parking brake and move the blade-control switch (PTO) to the OFF position. Move either motion-control lever (out of the NEUTRAL-LOCK position). Try starting the engine; the engine should not crank. Repeat for the other control lever.

3. Sitting on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Now start the engine. While the engine is running, release the parking brake, engage the blade-control switch (PTO) and rise slightly from the seat; the engine should shut off.

4. Sitting on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should shut off. Repeat for the other motion control.

5. Sitting on the seat, disengage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to the NEUTRAL-LOCK position. Try starting the engine; the engine should not crank.

Note: The engine will kill if the traction control levers are moved with the parking brake engaged.

To stop, pull the motion-control levers to the NEUTRAL position.

1. Release the parking brake; refer to Releasing the Parking Brake.

2. Move the levers to the center, unlocked position.

3. To go forward, slowly push the motion-control levers forward (Figure 25).

   

   Figure 25

1. Move the levers to the center, unlocked position.

2. To go backward, slowly pull the motion-control levers rearward (Figure 26).

   

   Figure 26

The transport lock has 2 positions, and is used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the TRANSPORT position of the mower deck (Figure 27).

Figure 27

Transport Lock Positions

1. Transport lock
2. Lock position— The mower deck will lock into transport position.
3. Unlock position— The mower deck does not lock into Transport position.

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 moving the clevis pin into different hole locations.

1. Move the transport lock to the lock position.

2. Push on the deck-lift pedal with your foot and raise the mower deck to the transport position (also the 140 mm (5–1/2 inch) cutting-height position); refer to Figure 28.

3. To adjust, rotate the pin 90° and remove the pin from the height-of-cut bracket (Figure 28).

4. Select a hole in the height-of-cut bracket corresponding to the height of cut desired, and insert the pin (Figure 28).

5. Push on the deck lift, pull back on the transport lock, and slowly lower the mower deck.

   

   Figure 28

   1. Deck-lift pedal
   2. Height-of-cut pin
   3. Transport lock

This is the full rear position. The suggested use for this position is as follows:

• Use for short, light grass mowing conditions.

• Use in dry conditions.

• Use for smaller grass clippings.

• Use to propel grass clippings farther away from the mower.

  

  Figure 33

Use this position when bagging. Always align it with the blower opening.

Figure 34

This is the fully open position. The suggested use for this position is as follows:

• Use in tall, dense grass mowing conditions.

• Use in wet conditions.

• Use to lower the engine-power consumption.

• Use to allow increased ground speed in heavy conditions.

• This position offers benefits similar to those of the Toro SFS mower.

  

  Figure 35

The slots for the rear-shock assemblies have detent positions for reference. You can position the rear-shock assemblies anywhere in the slot, not just in the detent positions.

The following graphic shows the position for a soft or firm ride and the different detent positions (Figure 38).

Figure 38

1. Firmest position
2. Softest position
3. Detents in the slots

Note: Ensure that the left and right rear-shock assemblies are always adjusted to the same positions.

Adjust the rear-shock assemblies (Figure 39).

Figure 39

The front-shock assembly is set at the middle position and is normally not adjusted.

To adjust the front-shock assembly, open the floor pan and adjust it by using a spanner wrench (Toro Part No. 132-5069) or a slip-joint pliers (Figure 40).

Figure 40

1. Middle position
2. Firm ride
3. Soft ride

For best mowing and maximum air circulation, operate the engine at the FAST throttle 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. Always try to have 1 side of the mower free from uncut grass, which allows air to be drawn into the mower.

Cut the grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best to use. When cutting grass longer than 15 cm (6 inches) tall, you may want to cut the lawn twice to ensure that there is an acceptable quality of cut.

It is best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Alternate the mowing direction to keep the grass standing straight. This also helps disperse clippings, which enhances decomposition and fertilization.

Normally, mow every 4 days. However, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again 2 days later at a lower height setting.

To improve cut quality, use a slower ground speed in certain conditions.

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short.

If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting.

If you must stop the motion of the machine while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.

Clean clippings and dirt from the underside of the mower after each use. If grass and dirt buildup inside the mower, the cutting quality will eventually become unsatisfactory.

Maintain a sharp blade throughout the cutting season, because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

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 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. Clean the grease fittings with a rag. Make sure that you 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 the bearings.

5. Wipe up any excess grease.

Adding Light Oil or Spray Lubrication

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	Lubricate the mower deck lift pivots.

Deck lift pivots.

Figure 45

Important: Make sure that the cutting unit spindles are full of grease weekly.

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. Grease the mower deck idler-pulley pivot until grease comes out the bottom (Figure 46).

4. Grease the 3 spindle bearings until grease comes out (Figure 46).

   

   Figure 46

5. Grease the drive-belt-idler arm (Figure 46).

   

   Figure 47

6. 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.

7. Remove the hex plug.

8. Thread a grease fitting into the hole.

9. Pump grease into the fitting until it oozes out around the top bearing.

10. Remove the grease fitting from the hole.

11. Install the hex plug and dust cap (Figure 48).

    

    Figure 48

12. Grease the caster-wheel bearings (Figure 48).

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

   

   Figure 49

   1. Seal guard
   2. Spacer nut with wrench flats

2. Raise the front of the machine up, and support it with jack stands (or equivalent support) just high enough to allow the front wheels to turn freely.

3. Remove the caster wheel from the caster forks.

4. Remove the seal guards from the wheel hub.

5. Remove a spacer nut from the axle assembly in the caster wheel.

   Note: Thread-locking adhesive has been applied to lock the spacer nuts to the axle.

6. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

7. Pry out seals, and inspect the bearings for wear or damage and replace them if necessary.

8. Pack the bearings with a general-purpose grease.

9. Insert 1 bearing and 1 new seal into the wheel.

   Note: Replace the seals.

10. If the axle assembly has had both spacer nuts removed (or broken loose), apply thread-locking adhesive to 1 spacer nut and thread it onto the axle with the wrench flats facing outward.

    Note: Do not thread the spacer nut all the way onto the end of the axle. Leave approximately 3 mm (1/8 inch) from the outer surface of the spacer nut to the end of the axle inside the nut.

11. Insert the assembled nut and axle into the wheel on the side of the wheel with the new seal and bearing.

12. With the open end of the wheel facing up, fill the area inside the wheel around the axle full of general-purpose grease.

13. Insert the second bearing and a new seal into the wheel.

14. Apply thread-locking adhesive to the 2nd 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 it, then torque it to 2 to 3 N∙m (20 to 25 in-lb).

    Note: Make sure that the axle does not extend beyond either nut.

16. Install the seal guards over the wheel hub and insert the wheel into the caster fork. Install the caster bolt and tighten the nut fully.

17. Remove the jack stands.

Important: To prevent seal and bearing damage, check the bearing adjustment often. Spin the caster wheel. The wheel should not spin freely (more than 1 or 2 revolutions) or have any side play. If the wheel spins freely, adjust the torque on spacer nut until there is a slight amount of drag. Apply thread-locking adhesive.

Note: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SG, SH, SJ, or higher)

Crankcase Capacity: with a filter change, 2.3 L (2.4 US qt); without a filter change, 2.1 L (2.2 US qt)

Viscosity: See the table below.

Figure 51

Note: Use of multi-grade oils (5W-20, 10W-30, or 10W-40) will increase oil consumption. Check the oil level more frequently when using them.

Make sure 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(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type : NGK BPR4ES or equivalent

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plugs

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 that the air cleaner is dirty.

Set the gap to 0.76 mm (0.030 inch).

Figure 58

Installing the Spark Plugs

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

Figure 59

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

5. Install the spark arrester on the exhaust outlet.

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

1. Disengage the 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. Allow the machine to cool down.

4. Close the fuel-shutoff valve under the seat.

   

   Figure 60

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

5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 60).

6. Remove the filter from the fuel lines.

7. Install a new filter and move the hose clamps close to the filter (Figure 60).

8. Open the fuel-shutoff valve.

Important: Install the fuel line hoses and secure 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 and circuit for a malfunction or short.

The fuses are located on right console next to the seat (Figure 63).

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

2. Install a new fuse (Figure 63).

   

   Figure 63

   1. Optional accessory (15 A)
   2. Charge (25 A)
   3. PTO (10 A)
   4. Main (25 A)
   5. Console

Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged.

Check that both the mounting hardware and the knobs are in good working condition. Make sure that the knobs are fully engaged with the ROPS in the raised position. The upper hoop of the roll bar may need to be pushed forward or pulled rearward to get both knobs fully engaged.

Figure 64

1. ROPS knob (locked position)
2. Pull the ROPS knob out and rotate it 90° to change the roll bar position.
3. Roll bar in the upright position
4. Roll bar in the folded position

1. Disengage the blade-control switch (PTO).

2. Drive to an open flat area, move the motion-control levers to the NEUTRAL-LOCK position.

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.

6. If it tracks to the right, loosen the bolts and adjust the left stop plate backward on the left T-slot until the machine tracks straight (Figure 65).

7. If it tracks to the left, loosen the bolts and adjust the right stop plate backward on the right T-slot until the machine tracks straight (Figure 65).

8. Tighten the stop plate (Figure 65).

   

   Figure 65

   Left control lever shown

   1. Control lever
   2. Bolt
   3. Stop plate

Maintain the air pressure in the rear tires at 90 kPa (13 psi). Uneven tire pressure can cause uneven cut. Check the tires when they are cold, to get the most accurate pressure reading.

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

Figure 66

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 286 to 352 N∙m (211 to 260 ft-lb).

Note: Do not use anti-seize compound on the wheel hub.

Figure 67

1. Slotted nut

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. Remove the dust cap from the caster and tighten the locknut (Figure 68).

4. Tighten the locknut until the spring washers are flat and then back off a 1/4 turn to properly set the pre-load on the bearings (Figure 68).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 68.

5. Install the dust cap (Figure 68).

   

   Figure 68

   1. Spring washers
   2. Locknut
   3. Dust cap

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.

Figure 69

1. Armature
2. Field shell
3. Rotor
4. Brake-mounting bolt
5. Brake spacer
6. Re-gap shim
7. Brake pole

Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 75).

Figure 75

Before each use, remove any buildup of grass, dirt, or other debris from the engine screen. This will help ensure adequate cooling, correct the engine speed, and will reduce the possibility of overheating and mechanical damage to the engine (Figure 76).

1. Disengage the PTO 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. Remove the air-intake screen, recoil starter, and fan housing (Figure 76).

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

5. Install the air-intake screen, recoil starter, and fan housing (Figure 76).

   

   Figure 76

   1. Engine guard
   2. Engine air-intake screen
   3. Bolt
   4. Fan housing
   5. Screw

1. Disengage the PTO 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. Move the seat forward.

4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 77).

5. Position the seat.

   

   Figure 77

   1. Hydraulic-unit shrouds

1. Drive the machine onto a level surface.

2. Disengage the blade-control switch (PTO), move the motion-control levers to the Neutral-locked position, and engage the parking brake.

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

4. Raise the back of the machine up and support the machine with jack stands.

   Danger

   Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

   • Use jack stand when supporting machine.

   • Do not use hydraulic jacks.

5. Remove the rear tires from the machine.

6. Remove any debris from the brake area.

7. Rotate the drive-wheel-release handle to the released position.

8. Check to see if there is a visible gap between the L-bracket and the linkage stop (Figure 78).

   

   Figure 78

   Left Side Shown

   1. L-bracket
   2. Linkage stop
   3. Gap
   4. Rear linkage assembly
   5. Caliper
   6. Wheel hub

9. Disengage the parking brake, the lever should be in the down position.

10. Turn the wheel hub by hand in both directions relative to the caliper; the wheel hub should move freely between the caliper.

11. If a gap is needed or the wheel hub does not move freely:

    1. Disengage the parking brake.

    2. Disconnect and fine-tune the rear linkage assembly:

       • Shorten the link to create a gap.

       • Lengthen the link to allow wheel hub movement.

    3. Reconnect the rear linkage assembly.

12. Engage the parking brake and check the gap.

13. Repeat steps 9 through 13 until a visible gap is achieved and the wheel hub rotates freely.

14. Repeat this procedure for the brake on the opposite side.

15. Rotate the drive-wheel-release handle to the operating position.

16. Install the rear tires and torque the lug nuts; refer to Checking the Wheel Lug Nuts.

17. Remove the jack stands.

Replace the belt if it is worn. The signs of a worn belt include squealing while the belt is rotating; the blades slipping while cutting grass; and frayed edges, burn marks, and cracks on the belt.

1. Disengage the PTO, move the motion-control levers to the neutral-locked 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. Lower the mower to the 76 mm (3 inch) height of cut.

4. Remove the belt covers (Figure 79).

   

   Figure 79

5. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 80).

6. Remove the belt from the mower-deck pulleys.

7. Remove the belt guide on the spring-loaded idler arm shown in Figure 80.

8. Remove the existing belt.

9. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 80).

   

   Figure 80

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Ratchet
   5. Square hole in the idler arm for the ratchet
   6. Idler-grease fitting
   7. Belt guide

10. Install the belt guide on the idler arm shown in Figure 80.

11. Using the ratchet in the square hole, install the idler spring (Figure 80).

    Note: Make sure that the spring ends are seated in the anchor grooves.

12. Install the belt covers (Figure 81).

    

    Figure 81

1. Disengage the PTO 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. Remove the mower belt; refer to Replacing the Mower Belt.

4. Raise the machine and support it with jack stands (Figure 82).

   

   Figure 82

   1. Idler pulley
   2. Clutch pulley
   3. Pump-drive belt
   4. Right hydraulic-pump pulley
   5. Left hydraulic-pump pulley
   6. Square hole in idler arm
   7. Idler spring

5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 82).

6. Unhook the idler spring from the frame (Figure 82).

7. Remove the belt from the hydraulic-unit-drive pulleys and the engine pulley.

8. Install the new belt around the engine pulley and the 2 drive pulleys.

9. Using a ratchet in the square hole in the idler arm, install the idler spring to the frame (Figure 82).

10. Install the mower belt; refer to Replacing the Mower Belt.

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 PTO, move the motion-control levers to the NEUTRAL-LOCKED 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. Loosen the bolts and flange nuts installed in the levers (Figure 83).

4. Align the levers front-to-rear position by bring the levers together to the NEUTRAL position and slide them until they are aligned, then tighten the bolts (Figure 84).

   

   Figure 83

   1. Bolt
   2. Handle
   3. Control lever
   4. Nut
   

   Figure 84

Located on either side of the fuel tank, below the seat are the pump-control linkages. Rotating the pump linkage with a 1/2–inch wrench allows fine-tuning adjustments so that the machine does not move into NEUTRAL position. Any adjustments should be made for neutral positioning only.

1. Prior to starting the engine, push the deck-lift pedal and remove the height-of-cut pin.

2. Lower the deck to the ground.

3. Raise the rear of machine up and support with jack stands (or equivalent support).

   Note: Raise the machine just high enough to allow drive wheels to turn freely.

4. Remove the electrical connection from the seat safety switch, located under the bottom cushion of the seat.

   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 wiring harness.

6. Start the engine, run it at full throttle, and release the brake.

   Note: The brake must be engaged and motion-control levers out to start engine. You do not have to be in the seat because of the jumper wire being used.

7. Run the unit at least 5 minutes with the drive levers at full forward speed to bring hydraulic fluid up to operating temperature.

   Note: The motion-control lever needs to be in NEUTRAL while making any necessary adjustments.

8. Bring the motion-control lever into the NEUTRAL position.

9. Adjust the pump-control-rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (Figure 85).

   

   Figure 85

   1. Double nuts

10. Move the motion-control levers to the REVERSE position and while applying slight pressure to the lever, allow the reverse-indicator springs to bring the levers back to NEUTRAL.

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

11. Shutoff the unit, remove the jumper wire from the wire harness and plug the connector into the seat switch.

12. Remove the jack stands.

13. Raise the deck and install the height-of-cut pin.

14. Check that the machine does not creep in NEUTRAL with the park brakes disengaged.

You can adjust the top damper-mounting bolt to obtain a more desired motion-control lever resistance. See Figure 86 for mounting options.

Figure 86

Right motion control shown

1. Torque the locknut to 23 N∙m (17 ft-lb). The bolt must protrude past the end of the locknut after torquing.
2. Most resistance (firmest feel)
3. Damper
4. Medium resistance (medium feel)
5. Least resistance (softest feel)

You can adjust the flanged nut to obtain the desired motion-control lever resistance when moving it to the neutral-lock position. See Figure 87 for adjustment options.

1. Loosen the jam nut.

2. Tighten or loosen the flanged nut to the desired feel.

   Note: For more resistance, tighten the flanged nut. For less resistance, loosen the flanged nut

3. Tighten the jam nut.

   

   Figure 87

   1. Flanged nut
   2. Jam nut

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

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

Each Hydraulic System Fluid Capacity: 1.5 L (1.59 US qt) per side with filter change

Maintain sharp blades throughout the cutting season, because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.

Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, keep extra blades on hand.

Before servicing or removing the mower deck, lock out the spring-loaded deck arms.

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

2. Remove the height-adjustment pin and lower the deck to the ground.

3. Place the height-adjustment pin in the 7.6 cm (3 inch) cutting-height location.

4. Remove the belt covers.

5. Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 102).

6. Rotate the deck idler clockwise and remove the mower belt (Figure 102).

   

   Figure 102

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Ratchet
   5. Square hole in the idler arm for the ratchet
   6. Idler grease fitting
   7. Belt guide

7. Remove and retain the hardware on both sides of the deck as shown in Figure 103.

   

   Figure 103

   1. Right stabilizer
   2. Deck strut (right side shown)
   3. Remove the rear deck lift attachment shoulder bolt and nut.
   4. Remove the front deck lift attachment shoulder bolt and nut.

8. Raise the deck struts and secure them in the up position. Slide the deck out to the right side of the machine.

1. Remove the locknut, bolt, spring, and spacer holding the deflector to the pivot brackets (Figure 104). Remove the damaged or worn grass deflector.

   

   Figure 104

   1. Bolt
   2. Spacer
   3. Locknut
   4. Spring
   5. Spring installed
   6. Grass deflector
   7. J hook end of spring

2. Place the spacer and the spring onto the grass deflector. Place one J end of the spring behind the deck edge.

   Note: Make sure one J end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 104.

3. Install the bolt and the nut. Place one J hook end of the spring around the grass deflector (Figure 104).

   Important: The grass deflector must be able to rotate. Lift the deflector up to the full open position and ensure that it rotates into the fully down position.

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.

Note: Do not clean the shock assemblies with pressurized water.

Figure 105

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