48in, 52in, or 60in TITAN® HD 1500, 2000, or 2500 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 a fuel stabilizer is used.

• Do not add oil to gasoline.

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 gasoline stabilizer/conditioner to the gasoline.

  Note: A 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.

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

5. Ensure that there is empty space in the tank to allow the gasoline to expand (Figure 7).

   

   Figure 7

Before you start the engine and use the machine, check the oil level in the engine crankcase. For Kawasaki engines refer to Servicing a Kawasaki® Engine, for Kohler engines refer to Servicing a Kohler® Engine, and for Toro engines refer to Servicing a Toro Engine.

Important: Ensure that the seat is secured to the machine.

1. To lower the roll bar, apply forward pressure to the upper part of the roll bar.

2. Pull both knobs out and rotate them 90 degrees so they are not engaged (Figure 8).

3. Lower the roll bar to the down position (Figure 8).

   

   Figure 8

   1. Roll bar in the upright position
   2. ROPS knob in the latched position
   3. Pull the ROPS knob out.
   4. Rotate the ROPS knob 90 degrees.
   5. ROPS knob in the unlatched position
   6. Roll bar in the folded position

4. To raise the roll bar, raise the roll bar to the operating position and rotate the knobs until they move partially into the grooves (Figure 8).

5. Raise the roll bar to the full upright position while pushing on the upper roll bar so that the pins snap into position when the holes align with the pins (Figure 8).

6. Push on the roll bar and ensure that both pins are engaged.

Important: Always use the seat belt with the roll bar in the raised position.

The seat can move forward and backward (Figure 11). Position the seat where you have the best control of the machine and are most comfortable.

Figure 11

The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

To adjust it, turn the knob in front either direction to provide the best comfort (Figure 12).

Figure 12

1. Seat-suspension knob

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.

Use only Toro approved attachments and accessories.

If more than one accessory-mount kit (i.e. bucket kit or universal mount kit) is added to any of the 4 locations shown in Figure 13, add a front-weight kit. Contact your authorized service dealer for the front-weight kit.

Figure 13

1. Add a front-weight kit when 2 or more accessory-mount kits are installed at these positions.

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

Setting the Parking Brake

Warning

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

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

Figure 14

Releasing the Parking Brake

Figure 15

The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.

Engaging the Blade-Control Switch (PTO)

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

Figure 16

Disengaging the Blade-Control Switch (PTO)

Figure 17

You can move the throttle control between FAST and SLOW positions (Figure 18).

Always use the FAST position when turning on the mower deck with the blade-control switch (PTO).

Figure 18

Use the choke to start a cold engine.

1. If the engine is cold, use the choke to start the engine.

2. Pull up the choke knob to engage the choke before using the ignition switch (Figure 19).

3. Push down the choke knob to disengage the choke after starting the engine (Figure 19).

   

   Figure 19

   1. ON position
   2. OFF position

1. Turn the ignition key to the START position (Figure 20).

   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 20

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

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

2. Move the motion controls to 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 17).

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

   

   Figure 21

6. Turn the ignition key to the START position (Figure 22).

   Note: 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, 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 22

   1. Off
   2. Run
   3. Start

Note: Refer to Figure 40 to determine which engine you have.

Shutting Off Kawasaki and Kohler Engines

Let the engine idle at slow throttle for 60 seconds before turning the ignition switch off.

Figure 23

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. Remove the key as the fuel pump may run and cause the battery to lose charge.

Shutting Off Toro Engines

Note: Ensure the throttle is in the FAST position before shutting off the engine.

Figure 24

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. Remove the key as the fuel pump may run and cause the battery to lose charge.

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.

Using the Motion-Control Levers

Figure 25

1. Motion-control lever—NEUTRAL-LOCK position
2. Center, unlocked position
3. Forward
4. Backward
5. Front of machine

Whenever you change the height-of-cut, adjust the height of the anti-scalp rollers.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and 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.

   

   Figure 30

   2500 series mower deck shown

   1. Anti-scalp roller
   2. Spacer
   3. Bushing
   4. Flange nut
   5. Bolt
   

   Figure 31

   1500 and 2000 series mower deck shown

   1. Flange nut
   2. Bolt
   3. Bushing
   4. Anti-scalp roller
   5. Spacer

Install the side bumpers in the top holes when operating in a height of cut higher than 64 mm (2-1/2 inches) and in the center holes when operating in a height of cut lower than 64 mm (2-1/2 inches).

Note: When the bumpers become worn, switch the bumpers to the opposite sides of the mower and flip them over. This allows the bumpers to be used longer before replacing them.

1. Disengage the blade-control switch (PTO), turn the ignition key to off, move the levers to the NEUTRAL-LOCK position, apply the parking brake, and remove the key.

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

3. Raise the mower to the transport position.

4. Remove the bolts and nuts from each bumper (Figure 32).

   

   Figure 32

   1. Bolt
   2. Bumper
   3. Nut

5. Move each bumper to the desired position and secure them with the bolts and nuts.

   Note: Use only the top or center sets of holes to adjust the bumpers. Use the bottom holes when switching sides, at which time they become the top holes on the other side of the mower.

To stop the machine, move the motion-control levers to neutral and then to the NEUTRAL-LOCK position, disengage the blade-control switch (PTO), and turn the ignition key to the OFF position.

Set the parking brake when you leave the machine; refer to Setting the Parking Brake. Remove the key from the ignition switch.

The mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

The fuel-shutoff valve is located behind the seat.

Close the fuel-shutoff valve for transport, maintenance, and storage.

Ensure that the fuel-shutoff valve is open when starting the engine.

Figure 33

1. ON position
2. OFF position

The drive-wheel-release valves are located on the left and right sides underneath the engine deck.

1. Disengage the blade-control switch (PTO), turn the ignition key to off, move the levers to the NEUTRAL-LOCK position, apply the parking brake, and remove the key.

2. Locate the bypass levers behind the seat, down on the left and right side of the frame.

3. To push the machine, move both bypass knobs rearward and lock them into place (Figure 34).

4. Disengage the parking brake before pushing the machine.

   

   Figure 34

   1. Front of the machine
   2. Rotate bypass release knob counterclockwise to loosen.
   3. Lever position for operating the machine
   4. Pull the lever in this direction to push the machine.
   5. Lever position for pushing the machine
   6. Rotate the bypass-release knob clockwise to tighten.
   7. Engine
   8. Release lever

5. To run the machine, move the bypass knobs to the FORWARD position and lock them into place (Figure 34).

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 you are 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. Use the metal tie-down loops on the machine to securely fasten the it to the trailer or truck with straps, chains, cable, or ropes (Figure 35).

   

   Figure 35

   1. Tie-down loops

Use extreme caution when loading or unloading the machine onto a trailer or a truck. Use a full-width ramp that is wider than the machine for this procedure. Back the machine up the ramps and drive it forward down the ramps (Figure 36).

Figure 36

1. Back the machine up the ramps.
2. Drive the machine forward down the ramps.

Important: Do not use narrow individual ramps for each side of the machine.

Ensure that the ramp is long enough so that the angle with the ground does not exceed 15 degrees (Figure 37). On flat ground, this requires a ramp to be at least 4 times as long as the height of the trailer or truck bed to the ground. 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.

Figure 37

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15 degrees
4. The 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

• Before repairing the machine do the following:

  • Disengage the drives.

  • Set the parking brake.

  • Shut off the engine and remove the key.

  • Disconnect the spark-plug wire.

• 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 the machine or fuel near flames or drain the fuel indoors.

• Do not allow untrained personnel to service the machine.

• Use jack stands to support the machine and/or 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, especially the blade-attachment bolts. Replace all worn or damaged decals.

• Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their proper operation regularly.

• To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

• Check the parking brake operation frequently. Adjust and service as required.

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 and pump idler-pulley pivot with 1 or 2 pumps of grease (Figure 38).

4. For 1500 and 2000 Series machines, grease the front caster axles (Figure 38).

   

   Figure 38

   1. Pump-idler pivot
   2. Caster axle (1500 and 2000 Series machines only)
   3. Mower deck idler-pulley pivot (2500 Series machines only)

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

   

   Figure 39

   1. Seal guard
   2. Spacer nut with wrench flats

2. Remove the caster wheel from the caster forks.

3. Remove the seal guards from the wheel hub.

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

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

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

6. Pry out seals and inspect bearings for wear or damage and replace if necessary.

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

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

   Note: Replace the seals.

9. If both spacer nuts have been removed (or broken loose) from the axle assembly, apply a thread-locking compound to 1 spacer nut and thread it onto the axle with the wrench flats facing outward.

   Note: Do not thread the spacer nut all of 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.

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

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

12. Insert the second bearing and new seal into the wheel.

13. Apply a thread-locking compound to the second spacer nut and thread it onto the axle with the wrench flats facing outward.

14. Torque the nut to 8 to 9 N∙m (75 to 80 in-lb), loosen the nut, 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.

15. Install the seal guards over the wheel hub and insert wheel into the caster fork.

16. Install the caster bolt and tighten the nut fully.

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

This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 41, you have a Kawasaki engine.

Important: Refer to your engine manufacturer’s information for additional maintenance procedures.

Figure 41

Servicing the Engine Oil

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

Crankcase Capacity: with a filter change, 2.1 L (71 oz); without a filter change, 1.8 L (61 oz)

Viscosity: See the table below.

Figure 43

Note: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.

Checking the Engine-Oil Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	For Kawasaki engines—check the engine-oil level.

Note: Check the oil when the engine is cold.

Warning

Contact with hot surfaces may cause personal injury.

Keep hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces.

Important: Do not overfill the crankcase with oil because that could damage engine. Do not run engine with oil below the Low mark because the engine may be damaged.

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 (Figure 44).

   

   Figure 44

Changing the Engine Oil

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	For Kawasaki engines—change the engine oil(more often in dirty or dusty conditions).

Note: Dispose of the used oil at a recycling center.

1. Start the engine and let it run for 5 minutes.

   Note: This warms the oil so that it drains better.

2. Park the machine so that the rear is slightly lower than the front to ensure that the oil drains completely.

3. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake.

4. Shut off the engine, remove the key, and wait for all moving parts to stop before leaving the operating position (Figure 45).

   

   Figure 45

5. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 46).

   

   Figure 46

6. Start the engine and drive to a flat area.

7. Check the oil level again.

Changing the Engine-Oil Filter

Maintenance Service Interval	Maintenance Procedure
Every 200 hours	For Kawasaki engines—change the engine-oil filter(more often in dirty or dusty conditions).

1. Drain the oil from the engine; refer to Changing the Engine Oil.

2. Change the engine-oil filter (Figure 47).

   

   Figure 47

   Note: Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra 3/4 turn.

3. Fill the crankcase with the proper type of new oil; refer to Servicing the Engine Oil.

Servicing the Spark Plug

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	For Kawasaki engines—replace or clean and gap the spark plug.

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 of Spark Plug: NGK^® BPR4ES or equivalent

Air Gap: 0.76 mm (0.03 inch)

Removing the Spark Plug

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

2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set the parking brake.

3. Locate and remove the spark plugs (Figure 48).

   

   Figure 48

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 49

Installing the Spark Plug

Tighten the spark plug(s) to 22 N∙m (16 ft-lb).

Figure 50

This section is only for machines with Kohler engines. If your engine looks like the one shown in Figure 51, you have a Kohler engine.

Important: Refer to your engine manufacturer’s information for additional maintenance procedures.

Figure 51

Servicing the Engine Oil

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

Crankcase Capacity: 1.9 L (64 oz) when the filter is changed

Viscosity: See the table below.

Figure 54

Checking the Engine-Oil Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	For Kohler engines—check the engine-oil level.

1. Park the machine on a level surface, disengage the blade-control switch, shut off the engine, and remove the key.

2. Make sure that the engine is shut off, level, and is cool, so the oil has time to drain into the sump.

3. Check the engine-oil level (Figure 55).

   

   Figure 55

Changing the Engine Oil and the Engine-Oil Filter

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	For Kohler engines—change the engine oil and the engine-oil filter.

Note: The drain plug is attached to the drain hose.

Note: Dispose of the used oil at a recycling center.

Fill with oil as specified in the “Viscosity Grades” table (Figure 54).

1. Park the machine, so that the drain side is slightly lower than the opposite side, to ensure that the oil drains completely.

2. Disengage the blade-control switch and move the motion controls outward to the PARK position.

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

   

   Figure 56

4. Torque the plug to 14 N∙m (10 ft-lb).

5. Change the engine-oil filter as shown in Figure 57.

   

   Figure 57

6. Slowly pour approximately 80% of the specified oil into the filler tube (Figure 58).

   

   Figure 58

Servicing the Spark Plug

Maintenance Service Interval	Maintenance Procedure
Every 200 hours	For Kohler engines—check the spark plug(s).
Every 500 hours	For Kohler engines—replace the spark plug(s).

The spark plug is RFI compliant. Equivalent alternate brand plugs can also be used.

Type: Champion XC12YC

Air Gap: 0.76 mm (0.03 inch)

Removing the Spark Plug

1. Disengage the blade-control switch, move the motion controls outward to the park position, shut off the engine, and remove the key.

2. Before removing the spark plug(s), clean the area around the base of the plug to keep dirt and debris out of the engine.

3. Remove the spark plug (Figure 59).

   

   Figure 59

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.

Note: 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 60

Installing the Spark Plug

Tighten the spark plug to 27 N∙m (20 ft-lb) as shown in Figure 61.

Figure 61

This section is only for machines with Toro engines. If your engine looks like what is shown in Figure 62, you have a Toro engine.

Figure 62

Servicing the Engine Oil

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

Crankcase Capacity: 2.4 L (80 oz) with oil filter

Viscosity: See the table below.

Figure 65

Checking the Engine-Oil Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	For Toro engines—check the engine-oil level.

Note: Check the oil when the engine is cold.

Warning

Contact with hot surfaces may cause personal injury.

Keep hands, feet, face, clothing, and other body parts away the muffler and other hot surfaces.

Important: Do not overfill the crankcase with oil, because damage to the engine may result. Do not run engine with oil below the Low mark, because the engine may be damaged.

1. Park the machine on a level surface, disengage the blade-control switch, shut off the engine, engage the parking brake, and remove the key.

2. Make sure that the engine is shut off, level, and is cool so that the oil has had time to drain into the sump.

3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 66).

Figure 66

Changing the Engine Oil and Oil Filter

Maintenance Service Interval	Maintenance Procedure
After the first 5 hours	For Toro engines—change the engine oil and filter.
Every 100 hours	For Toro engines—change the engine oil and oil filter(more often in dusty, dirty conditions).

Note: Dispose of the used oil at a recycling center.

1. Park the machine on a level surface to ensure the oil drains completely.

2. Disengage the PTO and engage the parking brake.

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

4. Drain the engine oil (Figure 67).

   

   Figure 67

5. Change the engine-oil filter (Figure 68).

   

   Figure 68

   Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn.

6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 69).

   

   Figure 69

Servicing the Spark Plug

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	For Toro engines—check the spark plug(s).
Every 200 hours	For Toro engines—replace the spark plug(s).

Make sure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark-plug wrench to remove and install 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: Champion RN9YC or NGK BPR6ES

Air gap: 0.76 mm (0.03 inch)

Removing the Spark Plug

1. 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.

   

   Figure 70

   Note: Due to the deep recess around the spark plug, blowing out the cavity with compressed air is usually the most effective method for cleaning. The spark plug is most accessible when the blower housing is removed for cleaning.

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 (0.030 inch).

Figure 71

Installing the Spark Plug

Tighten the spark plug(s) to 25 to 30 N∙m (19 to 22 ft-lb).

Figure 72

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

2. Wait for 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.

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

2. Remove the filter from the vent hose.

3. Insert a new filter into the end of the vent hose.

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 can cause fuel line damage.

The fuel filter is located near the engine on the left front of the engine.

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. Allow the machine to cool down.

4. Close the fuel-shutoff valve under the seat (Figure 33).

   

   Figure 73

   Kohler engine filter shown

5. Open the fuel-shutoff valve.

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 the right console next to the seat (Figure 76).

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

2. Install a new fuse (Figure 76).

   

   Figure 76

   1. Fuse cover
   2. Fuse holder
   3. Fuel-shutoff valve

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.

  Note: The upper hoop of the roll bar may need to be pushed forward or pulled rearward to fully engage both knobs (Figure 77 and Figure 78).

Figure 77

1. Roll bar in the upright position
2. ROPS knob in the latched position
3. Pull the ROPS knob out and rotate it 90 degrees.
4. Rotate the ROPS knob 90 degrees.
5. ROPS knob in the unlatched position
6. Roll bar in the folded position

Figure 78

1. Engaged
2. Partially engaged—do not operate with the ROPS in this position.

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

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

3. Move the throttle midway between the FAST and SLOW positions.

4. Move both motion-control levers forward until they both hit the stops in the T-slot.

5. Check which way the machine tracks.

6. If the machine tracks to the right, insert a 3/16-inch hex wrench through the access hole in the right front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever (Figure 79).

7. If the machine tracks to the left, insert a 3/16-inch hex wrench through the access hole in the right front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever (Figure 79).

8. Drive the machine and check the full forward tracking.

9. Repeat the adjustment until the desired tracking is obtained.

   

   Figure 79

   Left control lever shown

   1. Access hole on front cover panel
   2. Tracking screw

Maintain the air pressure in the front and 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.

Figure 80

Check and torque the wheel lug nuts to 122 to 136 N∙m (90 to 100 ft-lb).

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

Note: Make sure to follow this procedure when a brake component has been removed or replaced.

1. Drive the machine onto a level surface.

2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK position, and set 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. Setup the machine to be pushed by hand. Refer to Using the Drive-Wheel-Release Valves.

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

   Caution

   Raising the machine for service or maintenance relying solely on mechanical or hydraulic jacks could be dangerous. The mechanical or hydraulic jacks may not be enough support or may malfunction allowing the machine to fall, which could cause injury.

   Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

6. Engage and disengage the parking brake and check each drive tire to ensure that each brake engages and disengages.

7. If an adjustment is necessary, disengage the parking brake. Remove the cotter pin from the brake linkage shaft (Figure 81).

   

   Figure 81

   1. Cotter pin
   2. Parking brake
   3. Brake linkage shaft

8. Check both spring lengths as shown in Figure 82. If an adjustment is necessary, turn the top nut clockwise to shorten the spring and counterclockwise to lengthen it.

   

   Figure 82

   1. Top nut
   2. Spring
   3. 44 mm (1-3/4 inches)

9. Push the parking brake lever all the way forward and down.

10. Rotate the brake-linkage shaft until the end aligns with the hole in the lever.

    • Shorten the linkage by turning it clockwise.

    • Lengthen the linkage by turning it counterclockwise.

11. Insert the brake-linkage shaft into the parking-brake hole and secure with the cotter pin. Repeat step 6 and adjust if necessary.

12. When adjustment is complete, remove the jack stands or equivalent support and lower the machine.

13. Place the machine into the OPERATING position. Refer to Using the Drive-Wheel-Release Valves.

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 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. Lower the mower to the 76 mm (3 inch) height-of-cut.

4. Remove the belt covers (Figure 83).

   

   Figure 83

5. Remove the spring tension from the spring-loaded idler pulley. Refer to Figure 84 or Figure 86.

   Note: For 1500 and 2000 Series mower decks, use the spring removal tool (Toro Part No. 92–5771) to remove the spring from the mower-deck post (Figure 85).

   Note: For 2500 Series mower decks, use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 86).

6. Remove the belt from the mower-deck pulleys and the clutch pulley.

7. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 84 or Figure 86).

   

   Figure 84

   1500 and 2000 Series Mower Decks

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Spring
   

   Figure 85

   1500 and 2000 Series Mower Decks

   1. Spring-removal tool (Toro Part No. 92–5771)
   2. Idler spring
   3. Mower-deck post
   4. Idler arm
   5. Mower belt
   

   Figure 86

   2500 Series Mower Decks

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Ratchet
   5. Square hole in the idler arm for the ratchet

8. Install the idler spring (Figure 84 or Figure 86).

   Note: Make sure to seat the spring ends in the anchor grooves.

9. Install the belt covers (Figure 87).

   

   Figure 87

1. Disengage the blade-control switch (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 for Side Discharge Mower Decks or Replacing the Mower Belt for Rear Discharge Mower Decks.

4. Raise the machine and support it with jack stands (Figure 93).

5. Remove the clutch stop (Figure 92).

   

   Figure 92

   1. Clutch stop

6. Remove the idler spring from the post (Figure 93).

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

8. Install the new belt around the engine pulley and the 2 hydraulic-pump pulleys (Figure 93).

   

   Figure 93

   1. Idler pulley
   2. Idler-spring post
   3. Engine pulley
   4. Pump-drive belt
   5. Right hydraulic-pump pulley
   6. Left hydraulic-pump pulley

9. Install the clutch stop (Figure 92).

10. Install the mower belt; refer to Belt Maintenance.

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.

   Adjusting the height:

   You can adjust the motion control levers higher or lower for maximum comfort.

   1. Remove the hardware holding the control lever to the control-arm shaft.

      

      Figure 94

      1. Bolts
      2. Slotted hole
      3. Control lever
      4. Control-arm shaft

   2. Move the control lever to the next set of holes. Secure the lever with the hardware.

   3. Repeat the adjustment for the opposite control lever.

   Adjusting the Tilt

   1. Loosen the upper bolt holding the control lever to the control arm shaft.

   2. Loosen the lower bolt just enough to pivot the control lever fore or aft. Tighten both bolts to secure the control in the new position.

   3. Repeat the adjustment for the opposite control lever.

      

      Figure 95

3. If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage.

Located on either side of the machine, below the seat are the pump control linkages. Rotating the end nut with a 1/2 inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.

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

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

3. 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.

4. Temporarily install a jumper wire across the terminals in the connector of the main harness.

5. Start the engine. Run the engine at full throttle and release the parking brake.

   Note: Ensure that the parking brake is engaged and that the motion-control levers are out to start the engine. You do not have to be in the seat.

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

   Note: The motion-control lever must be in neutral while making any necessary adjustments.

7. Bring the motion-control levers into the NEUTRAL position.

8. Check and ensure that the control-plate tabs touch the return-to-neutral plates on the hydraulic units.

9. Adjust the pump-control-rod lengths by turning the nut in the appropriate direction until the wheels slightly creep in reverse (see Figure 96).

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.

    Note: You may need to remove the motion-control cover to gain access.

    

    Figure 96

    1. Nut
    2. Stationary plate
    3. Control plate
    4. Return-to-neutral plate
    5. Tabs touching return to neutral plate

11. Shut off the machine.

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

13. Remove the jack stands.

14. Raise the mower deck and install the height of cut pin.

15. Check and ensure that the machine does not creep in neutral with the park brake disengaged.

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

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

Hydraulic System Capacity (with filters removed): 4.45 L (150 oz)

Change the filters and oil at the same time. Do not use the oil again. Purge any air in the system after you install the new filters and add oil. Refer to Bleeding the Hydraulic System.

Repeat the bleeding process until the oil remains at the FULL COLD line in the reservoir after purging. Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system.

Installing the Hydraulic-System Filters

1. Apply a thin coat of oil on the surface of the rubber seal of each filter.

2. Turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 3/4 to 1 full turn.

3. Repeat for the opposite filter.

4. Install the filter guards over each filter that you previously removed.

5. Use the 3 screws to secure the filter guards.

6. Verify that the vent plugs are removed before adding the oil.

7. Slowly pour the specified oil through the expansion reservoir until oil comes out of 1 of the vent-plug holes.

8. Install the vent plug.

9. Torque the plug to 20 N∙m (15 ft-lb).

10. Continue to add oil through the expansion reservoir until oil comes out of the remaining vent-plug hole on the second transmission.

11. Install the opposite vent plug.

12. Torque the plug to 20 N∙m (15 ft-lb).

13. Continue to add oil through the expansion reservoir until it reaches the FULL COLD line on the expansion reservoir.

14. Proceed to Bleeding the Hydraulic System.

    Important: Failure to perform the Bleeding the Hydraulic System procedure after changing hydraulic filters and oil can result in irreparable damage to the transaxle drive system.

Figure 99

To ensure a superior quality of cut, keep the blades sharp. 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 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. Loosen the mower deck idler and remove the mower belt; refer to Belt Maintenance.

6. Remove the bolts and nuts from the front of the plate under the footrest.

7. Remove and retain the bolts and nuts on both sides of the machine (Figure 113).

   

   Figure 113

   1. Remove the nuts and bolts here.
   2. Remove the nuts and bolts here.

8. 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 114).

2. Remove the damaged or worn grass deflector (Figure 114).

   

   Figure 114

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

3. Place the spacer and the spring onto grass deflector.

4. Place 1 J-hook end of the spring behind the deck edge.

   Note: Make sure that 1 J-hook end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 114.

5. Install the bolt and the nut.

6. Place 1 J-hook end of the spring around the grass deflector (Figure 114).

   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 full 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.

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