Z Master® Professional 6000 Series Riding Mower

• Read the Operator's Manual and other training material.

• If the operator(s) or mechanic(s) cannot read the 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: substantial slip-resistant footwear, safety glasses, and hearing protection. Tie back long hair and do not wear jewelry.

• Inspect the area where the equipment is used, and remove all objects that 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.

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

• 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 machine under the influence of alcohol or drugs; do not operate the machine when sick or tired.

• 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 securely.

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

• 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 full-width ramps 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 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.

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 (Figure 7).

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

   Note: Do not fill the fuel tank completely full. Fill the fuel tank to the bottom of the filler neck.

   

   Figure 7

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

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

Note: The engine shuts off if you move the traction-control levers 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 an UNLOCK position for the transport position of the mower deck (Figure 24).

Adjust the height-of-cut from 25to140mm (1 to 5-1/2inches) in 6mm (1/4inch) 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 140mm or 5-1/2inch cutting-height position) as shown in 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. Height-of-cut pin
   3. Transport lock

This is the full rear position. Use this position for the following.

• Short, light grass mowing conditions.

• Dry conditions.

• Smaller grass clippings.

• Propelling grass clippings farther away from the mower.

  

  Figure 29

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

This is the full open position. Use this position for the following:

• Tall, dense grass mowing conditions.

• Wet conditions.

• Lowering the engine power consumption.

• Increased ground speed in heavy conditions.

  

  Figure 31

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

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 you have used in the past is generally the best to use. When cutting grass longer than 15.24 cm (6 inches) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about a third 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. 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 that 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 forward 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 build up inside the mower, the cutting quality eventually becomes 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.

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 come out the bottom (Figure 40).

4. Grease the 3 spindle bearings until grease comes out the lower seals (Figure 40).

   

   Figure 40

5. Grease the drive-belt idler arm (Figure 40).

   

   Figure 41

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 42).

    

    Figure 42

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

   

   Figure 43

   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.

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

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

Oil Capacity: with a filter change, 1.9 L (64 oz); with no filter change, 1.7 L (57 oz)

Viscosity: See the table below.

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 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^® BPR5ES or equivalent

Air Gap: 0.75 mm (0.03 inch)

For a Model with a Spark Arrester

1. Stop 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.

The fuel filter is located near the engine on the front or rear side 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. Wait for the machine to cool down.

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

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

   

   Figure 54

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

6. Remove the filter from the fuel lines.

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

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 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—15A
   2. Charge—25A
   3. PTO—10A
   4. Main—25A
   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 fully engage both knobs (Figure 58).

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

7. If the machine 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 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.

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.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK 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 the locknut (Figure 62).

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

   Important: Make sure that 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, you can remove the shim to extend the clutch life.

Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 69). This helps ensure adequate cooling, correct engine speed, and reduces the possibility of overheating and mechanical damage to the engine.

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

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

5. Install the 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 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. 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 that the brake is adjusted properly before adjusting.

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 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 and support the machine with jack stands.

   Danger

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

   • Use a jack stand when supporting the 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 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.

10. Turn the wheel hub by hand in both directions relative to the caliper.

    Note: 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. Connect the rear-linkage assembly.

12. Engage the parking brake and check the gap.

13. Repeat steps 9 through 13 until you achieve a visible gap 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.

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. 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

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 (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 (Figure 74).

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

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

12. Install the belt covers (Figure 75).

    

    Figure 75

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 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 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 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.

1. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK 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 in the front-to-rear position by bringing the levers together to the NEUTRAL position, slide them until they are aligned, and tighten the bolts (Figure 78).

   

   Figure 77

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

   Figure 78

5. If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Neutral-Lock Pivot.

The pump-control linkages are located on either side of the fuel tank, below the seat. Rotate the pump linkage with a 1/2 inch wrench for fine-tuning adjustments so that the machine does not move in neutral. Make any adjustments for neutral positioning only.

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

2. Raise the rear of machine 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: Engage the parking brake and move the motion-control levers out before starting the engine. You do not need 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.

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.

11. Remove the jumper wire from 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 when you disengage the parking brakes.

You can adjust the top damper mounting bolt to obtain a more desired motion-control lever resistance. See Figure 80 for mounting options.

You can adjust the flanged nut to obtain the desired motion-control lever resistance when you move them 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.

   Note: For more resistance, tighten the flanged nut.

   Note: 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 damage the hydraulic system.

Each Hydraulic System Oil Capacity: 1.5 L (52 oz) per side with filter change

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

1. Position the mower on a flat surface.

2. Disengage the blade-control switch (PTO), move the motion-control levers to the NEUTRAL-LOCK 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 the pressure of the drive tires.

   Note: Proper inflation pressure for the tires is 90 kPa (13 psi).

5. Position the mower deck 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, remove the key, and engage the parking brake.

3. Check the tire pressure in the drive tires.

   Note: Proper inflation pressure for the tires is 90 kPa (13 psi).

4. Position the transport lock in the latching position.

5. Push the deck-lift pedal all the way forward so that the deck latches at the 14 cm (5-1/2 inches) 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 inches) 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) as shown in Figure 86.

   Note: The measurement should read 7.6 mm (3 inches)

   

   Figure 86

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

10. For mower decks shown in Figure 87, fine-tune the adjustment nut on the front deck-lift assembly by turning it.

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

    

    Figure 87

    1. Adjustment nut
    2. Jam nut
    3. Rear deck adjustment
    4. Front deck adjustment

11. For mower decks shown in Figure 88, fine-tune the adjustment nut on the front deck-lift assembly by turning it (Figure 88).

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

    Note: If the front deck links do not have enough adjustment to achieve accurate cut height, you can utilize the single-point adjustment to gain more adjustment.

    

    Figure 88

    1. Adjustment nut
    2. Jam nut
    3. Rear deck adjustment
    4. Front deck adjustment

12. To adjust the single-point system, loosen the 2 bolts at the bottom of the height-of-cut plate (Figure 89).

    

    Figure 89

    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 90).

    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 gain some up and down adjustment on each of the 4 deck links.

14. Tighten the 2 bolts at the bottom of the height-of-cut plate (Figure 90).

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

    

    Figure 90

    1. Single-point adjustment bolt

15. Torque the 2 bolts to 37 to 45 N∙m (27 to 33 ft-lb).

16. On both sides of the deck, measure from the level surface to the back tip of the blade (position B) as shown in Figure 86.

    Note: The measurement should read 8.3 cm (3-1/4 inches)

17. Fine-tune the screw adjuster by turning it to get 8.3 mm (3-1/4 inches) height (Figure 88).

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

18. Measure until all 4 sides are the correct height.

19. Tighten all the nuts on the deck-lift-arm assemblies.

20. Lower the discharge chute.

1. Park the machine on a level surface, Disengage the blade-control switch (PTO), and set the parking brake.

2. Turn the ignition key to off. Remove the key, and disconnect the spark plug wires from the spark plugs.

1. Inspect the cutting edges (Figure 91).

2. If the edges are not sharp or have nicks, remove and sharpen the blade; refer to Removing the Blades and Sharpening the Blades.

3. Inspect the blades, especially in the curved area.

4. If you notice any cracks, wear, or a slot forming in this area, immediately install a new blade (Figure 91).

   

   Figure 91

   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-LOCK 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 92).

4. Measure from a level surface to the cutting edge, position A, of the blades (Figure 92).

   

   Figure 92

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

5. Rotate the opposite ends of the blades forward.

6. Measure from a level surface to the cutting edge of the blades at the same position as in step4.

   Note: The difference between the dimensions obtained in steps 4 and5 must not exceed 3mm (1/8inch).

   Note: If this dimension exceeds 3mm (1/8inch), the blade is bent and must be replaced.

   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.

   • Do not file or create sharp notches in the edges or surfaces of the blade.

Replace a blade if it hits an object, if the blade is out of balance, or if the blade 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 nonconformance with safety standards.

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

2. Remove the blade bolt, curved washer, and blade from the spindle shaft (Figure 93).

   

   Figure 93

   1. Sail area of the 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 94).

   Note: Maintain the original angle.

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

   

   Figure 94

   1. Sharpen at the original angle

2. Check the balance of the blade by putting it on a blade balancer (Figure 95).

   Note: If the blade stays in a horizontal position, the blade is balanced and ready to use.

   

   Figure 95

   1. Blade
   2. Balancer

3. If the blade is not balanced, file some metal off the end of the sail area only (Figure 93).

4. Repeat this procedure until the blade is balanced.

1. Install the blade onto the spindle shaft (Figure 96).

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

2. Install the spring disk and blade bolt (Figure 96).

   Note: Install the spring-disk cone toward the bolt head.

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

   

   Figure 96

   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-LOCK 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.