Z Master® Commercial 3000 Series Riding Mower

• Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) can not read manual language, it is the owner's responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to people or damage to property.

• Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Check that operator's presence controls, safety switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

• 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.

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes and hidden hazards.

• Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator's position.

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

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

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

• Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

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

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

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

• Keep hands and feet away from the cutting unit.

• Look behind and down before backing up to be sure of a clear path.

• Keep pets and bystanders away.

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

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

• Do not operate the mower 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.

• Do not remove the ROPS.

• The ROPS is an integral and effective safety device. Keep the ROPS on the machine and use the seat belt when operating the machine.

• Be certain that the seat belt can be released quickly in the event of an emergency.

• Check the area to be mowed where there are slopes, drop offs or water.

• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Keep the ROPS in safe operating condition by periodically thoroughly inspecting for damage and keeping all mounting fasteners tight.

• Replace a damaged ROPS. Do not repair or revise.

• Any alterations to a ROPS must be approved by the manufacturer.

• 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.

• Never remove fuel cap or add fuel with the engine running.

• Allow engine to cool before refueling.

• Never refuel the machine indoors.

• Never 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.

• Never fill containers inside a vehicle or on a truck or 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 refuel it on the ground. If this is not possible, then refuel such equipment with 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 fuel is spilled on clothing, change clothing immediately.

• Never overfill fuel tank. Replace fuel cap and tighten securely.

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

• Clean grass and debris from cutting unit, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near flame.

• Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

• Park the machine on level ground. Set the parking brake. Never 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 spark-plug wire before making any repairs. Disconnect the negative terminal first and the positive last. Reconnect the positive first and negative last.

• Use care when checking blades. Wrap the blade(s) or wear thickly-padded gloves, and use caution when servicing them. Only replace blades. Never 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 truck.

• Use full width ramps for loading machine into trailer or 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 gas stabilizer/conditioner to the gas.

  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.

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

2. Clean around the fuel tank cap and remove the cap. Add unleaded regular gasoline to the fuel tank, until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck. This space in the tank allows the gasoline to expand. Do not fill the fuel tank completely full.

3. Install the fuel tank cap securely. Wipe up any gasoline that may have spilled.

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

Figure 12

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

2. Move the motion controls to neutral locked 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 17

6. Turn the ignition key to the Start position (Figure 15). 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: Additional starting cycles may be required when starting the engine for the first time after the fuel system has been without fuel completely.

   

   Figure 18

   1. Off
   2. Run
   3. Start

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

Figure 19

Important: Make sure that the fuel shut off 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.

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 22).

   

   Figure 22

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

2. To go backward, slowly pull the motion control levers rearward (Figure 23).

   

   Figure 23

The transport lock has 2 positions and is used with the deck-lift pedal. There is a lock position and a unlock position for the transport position. The transport lock is used with the deck-lift pedal. Refer to Figure 24.

Figure 24

Transport Lock Positions

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

The height-of-cut is adjusted from 25to140mm (1 to 5-1/2inches) in 6mm (1/4inch) increments by relocating 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 140mm (5-1/2inch) cutting height position) (Figure 25).

3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 25).

4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired and, insert the pin (Figure 25).

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

   

   Figure 25

   1. Deck-lift pedal
   2. Cut of height pin
   3. Transport lock

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

• Use for short, light grass mowing conditions.

• Use in dry conditions.

• For smaller grass clippings.

• Propels grass clippings farther away from the mower.

  

  Figure 30

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

Figure 31

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

• Use in tall, dense grass mowing conditions.

• Use in wet conditions.

• Lowers the engine power consumption.

• Allows increased ground speed in heavy conditions.

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

  

  Figure 32

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 by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.

Cut grass slightly longer than normal to ensure the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than six inches tall, you may want to cut the lawn twice to ensure 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 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 midsummer, 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 the you must stop the forward motion of the machine while mowing, a clump of grass clippings may drop onto the 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 build up inside the mower, 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.

Lubricate the deck-lift pivots.

Figure 38

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 locked position, and set the parking brake.

2. Stop 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 come out the bottom (Figure 39).

4. Grease the 3 spindle bearings until grease comes out the lower seals (Figure 39).

   

   Figure 39

5. Grease the drive belt idler arm (Figure 39).

   

   Figure 40

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 and thread a grease fitting into the hole.

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

9. Remove the grease fitting from the hole.

10. Install the hex plug and dust cap (Figure 41).

    

    Figure 41

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

   

   Figure 42

   1. Seal guard
   2. Spacer nut with wrench flats

2. Raise the front of the machine up and support it with jack stands.

3. Remove the caster wheel from the caster forks.

4. Remove the seal guards from the wheel hub.

5. Remove 1 of the spacer nuts from the axle assembly in the caster wheel.

   Note: Note that thread locking adhesive has been applied to lock the spacer nuts to the axle. Remove the axle (with the other spacer nut still assembled to it) from the wheel assembly.

6. Pry out the seals, and inspect the 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: The seals must be replaced.

9. If the axle assembly has had both spacer nuts removed (or broken loose), apply a 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 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 of the wheel 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 adhesive to the second spacer nut and thread it onto the axle with the wrench flats facing outward.

14. Torque the nut to 8-9 N-m (75-80 in-lb), loosen, then re-torque to 2-3 N-m (20-25 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 the wheel into the caster fork. 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 thread locking adhesive.

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

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

Oil Capacity for 74959 engine: with a filter change, 1.65L (56 oz); with no filter change, 1.5L (51 oz)

Viscosity: See the table below.

Figure 45

Note: Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4 degrees C (40 degrees F).

Note: Synthetic oils will provide better starting in extreme cold below -23 degrees C (-10 degrees F).

Make sure 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 : Champion^® XC12YC, or equivalent

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plug

Important: Replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, cracks or reuse is questionable.

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 inches).

Figure 52

Installing the Spark Plug

Tighten the spark plug(s) to 24.4–29.8 N-m (18-22 ft.-lb).

Figure 53

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

2. Wait for the machine to cool.

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

4. If the screen is plugged, remove the arrester and shake loose any particles out of the arrester and clean the screen with a wire brush (soak in solvent if necessary). Install the arrester on an 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 locked position, and set the parking brake.

2. Stop 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. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

5. Close the fuel shutoff valve under the seat (Figure 54).

   

   Figure 54

   1. Fuel filter
   2. Hose clamp
   3. Fuel shutoff valve

6. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 54).

7. Remove the filter from the fuel lines.

8. Install a new filter and move the hose clamps close to the filter (Figure 54).

9. Open the fuel shutoff valve.

Note: It is important to reinstall 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.

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 hand console next to the seat (Figure 57).

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

3. Install a new fuse (Figure 57).

   

   Figure 57

   1. Optional accesory-15amp
   2. Charge-25amp
   3. PTO-10amp
   4. Main-25amp
   5. Console

Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace before operating if damaged.

Check that both the mounting hardware and the knobs are in good working condition. Make sure 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 58

1. ROPS knob (locked position)
2. Pull ROPS knob out and rotate 90 degrees to change 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 locked 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 rearward on the left T-slot until the machine tracks straight (Figure 59).

7. If it tracks to the left, loosen the bolts and adjust the right stop plate rearward on the right T-slot until the machine tracks straight (Figure 59).

8. Tighten the stop plate (Figure 59).

   

   Figure 59

   Left control lever shown

   1. Control lever
   2. Bolt
   3. Stop plate

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 60

Check and torque the wheel lug nuts to 122-129 N-m (90-95 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 on wheel hub.

Figure 61

1. Slotted nut

1. Disengage the blade-control switch (PTO), move the motion-control levers to the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove the dust cap from caster and tighten locknut (Figure 62).

4. Tighten the locknut until the spring washers are flat and then back off a 1/4turn to properly set the pre-load on the bearings (Figure 62).

   Important: Make sure the spring washers are installed correctly as shown in Figure 62.

5. Install the dust cap (Figure 62).

   

   Figure 62

   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 63

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

Remove any build-up of grass, dirt, or other debris from the oil cooler (Figure 69).

Figure 69

Before each use remove any build-up of grass, dirt, or other debris from the engine screen. This will help ensure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine (Figure 70).

1. Disengage the PTO and set the parking brake.

2. Stop 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 70).

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

5. Install air intake screen, recoil starter, and fan housing (Figure 70).

   

   Figure 70

   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. Stop 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 units (Figure 71).

5. Position the seat.

   

   Figure 71

   1. Hydraulic units

Check to make sure the brake is adjusted properly before adjusting.

Note: This procedure must be followed after the first 100 hours or when a brake component has been removed or replaced.

1. Drive the machine onto a level surface.

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

3. Stop 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. Refer to Using the Drive-Wheel-Release Valves.

8. Check to see if there is a visible gap between the L-bracket and the linkage stop (Figure 72).

   

   Figure 72

   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. Refer toUsing the Drive-Wheel-Release Valves.

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

17. Remove the jack stands.

Check the belts for squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks, and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn mower belt. Replace the mower belt if any of these conditions are evident.

1. Disengage the PTO, move the motion-control levers to the neutral locked position, and set the parking brake.

2. Stop 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 73).

   

   Figure 73

   1. Push tab down
   2. Remove belt cover

5. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 74).

6. Remove the belt from the mower deck pulleys.

7. Remove the belt guide on the spring loaded idler arm shown in Figure 74.

8. Remove the existing belt.

9. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 74).

   

   Figure 74

   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 74.

11. Using the ratchet in the square hole, install the idler spring (Figure 74).

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

12. Install the belt covers (Figure 75).

    

    Figure 75

    1. Position the belt cover
    2. Slide belt cover under the side catches
    3. Ensure the tab is under the metal catch

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Remove mower belt. Refer to Replacing the Mower Belt.

4. Raise the machine and support it with jack stands (Figure 76).

   

   Figure 76

   1. Idler pulley
   2. Clutch pulley
   3. Pump-drive belt
   4. Right hand hydraulic pump pulley
   5. Left hand 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 76).

6. Unhook the idler spring from the frame (Figure 76).

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

8. Install the new belt around 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 76).

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. Stop 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 77).

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 78).

   

   Figure 77

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

   Figure 78

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 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 the deck to the ground.

2. Raise the rear of machine up and support it with jack stands (or equivalent support) just high enough to allow the 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 wiring harness.

5. Start the engine.

   Note: The brake must be engaged and the motion-control levers must be out to start the engine. The operator does not have to be in the seat because of the jumper wire being used. Run the engine at full throttle and release the brake.

6. Run the machine at least 5 minutes with the motion-control levers at full forward speed to bring the hydraulic oil up to operating temperature.

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

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

8. 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 79).

   

   Figure 79

   1. Double nuts

9. 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.

10. Shut off the machine. Remove the jumper wire from wire harness and plug the connector into the seat switch.

11. Remove the jack stands.

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

13. Check that the machine does not creep in neutral with the park brakes disengaged.

The top damper-mounting bolt can be adjusted to obtain a more desired motion-control lever resistance. See Figure 80 for mounting options.

Figure 80

RH 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)

The flanged nut can be adjusted to obtain a more desired motion-control lever resistance when moving it to the neutral lock position. See Figure 81 for adjustment options.

1. Loosen the jam nut.

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

   For more resistance, tighten the flanged nut.

   For less resistance, loosen the flanged nut

3. Tighten the jam nut.

   

   Figure 81

   1. Flanged nut
   2. Jam nut

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

Important: Use oil specified. Other fluids could cause system damage.

Each Hydraulic System Oil Capacity: 52 ounces (1.5 l) per side with filter change

Note: Ensure the mower deck is leveled before matching the height-of-cut (HOC).

1. Position mower on a flat surface.

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

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

4. Check tire pressure of the tires. If needed, adjust to 90 kPa (13psi).

5. Position the mower to the 76mm (3inch) height-of-cut position.

1. Position the mower on a flat surface.

2. Stop engine, wait for all moving parts to stop, and remove key. Engage parking brake.

3. Check the tire pressure in the drive tires. Proper inflation pressure for tires is 90 kPa (13 psi). Adjust if necessary.

4. Position the transport lock in the latching position.

5. Push the deck-lift pedal all the way forward and the deck will latch at the 14 cm (5 1/2 inch) transport position (Figure 85).

   

   Figure 85

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

6. Insert the height adjustment pin into the 7.6 cm (3 inch) cutting height location.

7. Release the transport lock and allow the deck to lower to the cutting height.

8. Raise the discharge chute.

9. On both sides of the deck, measure from the level surface to the front tip of the blade (Postion A). The measurement should read 7.6 mm (3 inches) (Figure 86).

   

   Figure 86

   1. 7.6 cm (3 inches) at A is correct
   2. 8.3 cm (3 1/4 inches) at B is correct
   3. Measure here from the blade tip to hard surface
   4. Measure at A and B on both sides

10. If needed, loosen the whizlock nut on the side of the yoke and the jam nut on top. Fine tune the screw adjuster by turning it to get 7.6 mm (3 inch) height (see Figure 87).

    To increase the height, turn the adjuster screw clockwise; to decrease, turn counterclockwise.

    

    Figure 87

    1. Whizlock nut
    2. Adjuster screw
    3. Jam nut
    4. Yoke

11. If the front deck links do not have enough adjustment to achieve accurate cut height , the single point adjustment can be utilized to gain more adjustment.

12. To adjust the single point system, loosen the two bolts at the bottom of the height of cut plate. Refer to Figure 88.

    

    Figure 88

    1. Bolts at the bottom of the height-of-cut plate

13. If the deck is too low, tighten the single point adjustment bolt by rotating it clockwise. If the deck is too high, loosen the single point adjustment bolt by rotating it counterclockwise (Figure 89).

    Note: Loosen or tighten the single point adjustment bolt enough to move the height-of-cut plate mounting bolts at least 1/3 the length of the available travel in their slots. This will regain some up and down adjustment on each of the four deck links.

    

    Figure 89

    1. Single point adjustment bolt

14. Tighten the two bolts at the bottom of the height of cut plate (Figure 88). Torque to 37-45 N-m (27-33 ft-lb).

    Note: In most conditions, the back blade tip should be adjusted 6.4 mm (1/4 inch) higher than the front.

15. On both sides of the deck, measure from the level surface to the back tip of the blade (Postion B). The measurement should read 8.3 cm (3 1/4 inches) (Figure 86).

16. Fine tune the screw adjuster by turning it to get 8.3 mm (3–1/4 inches) height (Figure 87).

    To increase the height, turn the adjustment nut clockwise; to decrease, turn counterclockwise.

17. Measure until all four sides are the correct height. Tighten all the nuts on the deck-lift arm assemblies.

18. Lower discharge chute.

Park the machine on a level surface, disengage the blade control switch (PTO), and set the parking brake. Turn the ignition key to off. Remove the key.

1. Inspect the cutting edges (Figure 90). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Servicing the Cutting Blades.

2. Inspect the blades, especially the curved area (Figure 90). If you notice any damage, wear, or a slot forming in this area (Figure 90), immediately install a new blade.

   

   Figure 90

   1. Cutting edge
   2. Curved area
   3. Wear/slot forming
   4. Crack

1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position and set the parking brake.

2. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position.

3. Rotate the blades until the ends face forward and backward (Figure 91). Measure from a level surface to the cutting edge, position A, of the blades (Figure 91). Note this dimension.

   

   Figure 91

   1. Measure here from blade to hard surface
   2. Position A

4. Rotate the opposite ends of the blades forward.

5. Measure from a level surface to the cutting edge of the blades at the same position as in step3 above. The difference between the dimensions obtained in steps3 and4 must not exceed 1/8inch (3mm). If this dimension exceeds 1/8inch (3mm), the blade is bent and must be replaced; refer to Removing the Blades and Sharpening the Blades.

   Warning

   A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

   • Always replace bent or damaged blade with a new blade.

   • Never file or create sharp notches in the edges or surfaces of blade.

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

1. Hold the blade end using a rag or thickly-padded glove.

2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 92).

   

   Figure 92

   1. Sail area of blade
   2. Blade
   3. Curved washer
   4. Blade bolt

1. Use a file to sharpen the cutting edge at both ends of the blade (Figure 93).

   Note: Maintain the original angle.

   Note: The blade retains balance if the same amount of material is removed from both cutting edges.

   

   Figure 93

   1. Sharpen at the original angle

2. Check the balance of the blade by putting it on a blade balancer (Figure 94).

   Note: If the blade stays in a horizontal position, the blade is balanced and can be used.

   

   Figure 94

   1. Blade
   2. Balancer

3. If the blade is not balanced, file some metal off the end of the sail area only (Figure 94).

4. Repeat this procedure until the blade is balanced.

1. Install the blade onto the spindle shaft (Figure 95).

   Important: The curved part of the blade must be pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the spring disk and blade bolt (Figure 95).

   Note: The spring-disk cone must be installed toward the bolt head (Figure 95).

3. Torque the blade bolt to 115 to 150N-m (85 to 110ft-lb).

   

   Figure 95

   1. Sail area of the blade
   2. Blade
   3. Spring disk
   4. Blade bolt

1. Disengage the blade control switch (PTO), move the motion control levers to the neutral locked position, and set the parking brake.

2. Stop 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 oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.