Z Master® Professional 6000 Series Riding Mower

• Read the instructions carefully. Be familiar with the controls and the proper use of the equipment.

• Never allow children or people unfamiliar with these instructions to use the lawn mower. Local regulations can restrict the age of the operator.

• Never mow while people, especially children, or pets are nearby.

• Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers should seek and obtain professional and practical instruction. Such instruction should emphasize:

  • the need for care and concentration when working with ride-on machines;

  • control of a ride-on machine sliding on a slope will not be regained by the application of the control levers. The main reasons for loss of control are:

    • insufficient wheel grip, especially on wet grass;

    • being driven too fast;

    • inadequate braking;

    • the type of machine is unsuitable for its task;

    • lack of awareness of the effect of ground conditions, especially slopes;

    • incorrect hitching and load distribution.

• While mowing, always wear substantial, slip-resistant footwear and long trousers. Tie back long hair. Do not wear jewelry.

• Thoroughly inspect the area where you will use the equipment and remove all objects which the machine may throw at you.

• Warning–Fuel is highly flammable.

  • Store fuel in containers specifically designed for this purpose.

  • Refuel the machine outdoors only and do not smoke while refuelling.

  • Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

  • If you spill fuel, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any source of ignition until the fuel vapors have dissipated.

  • Replace all fuel tanks and container caps securely.

• Replace faulty silencers.

• Before using, always visually inspect to see that the blades, blade bolts, and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

• On multi-bladed machines, take care as rotating one blade can cause other blades to rotate.

• 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.

• Be alert, slow down, and use caution when making turns. Look behind and to the side before changing directions.

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all blade-attachment clutches and shift the transmission into neutral.

• Do not use on slopes greater than 15 degrees.

• Remember that there is no such thing as a safe slope. Travel on grass slopes requires particular care. To guard against overturning:

  • do not stop or start suddenly when on a slope;

  • use slow speeds on slopes and during tight turns;

  • stay alert for humps and hollows and other hidden hazards;

• Use care when pulling loads or using heavy equipment.

  • Use only approved drawbar hitch points.

  • Limit loads to those you can safely control.

  • Do not turn sharply. Use care when reversing the machine.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other than grass.

• When using any attachments, never direct discharge of material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with damaged guards or without safety protective devices in place.

• Do not change the engine governor settings or overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

• Before leaving the operator's position:

  • disengage the power takeoff and lower the attachments;

  • change into neutral and set the parking brake;

  • stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and disconnect the spark plug wire(s) or remove the ignition key

  • before clearing blockages or unclogging the chute;

  • before checking, cleaning, or working on the lawn mower;

  • after striking a foreign object. Inspect the lawn mower for damage and make repairs before starting and operating the equipment; if the machine starts to vibrate abnormally (check immediately).

• Disengage drive to attachments when transporting or not in use.

• Stop the engine and disengage drive to attachment

  • before fuelling;

  • before removing the grass catcher;

  • before adjusting the height unless you can adjust it from the operator's position.

• Reduce the throttle setting during engine run-out and, if the engine is provided with a shutoff valve, turn the fuel off at the conclusion of mowing.

• Keep all nuts, bolts and screws tight to be sure that the equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a building, where fumes can reach an open flame or spark.

• Allow the engine to cool before storing the machine in any enclosure.

• To reduce the fire hazard, keep the engine, silencer, battery compartment, and fuel storage area free of grass, leaves, or excessive grease.

• Check the grass catcher frequently for wear or deterioration.

• Replace worn or damaged parts for safety.

• If you must drain the fuel tank, do it outdoors.

• When machine is to be parked, stored or left unattended, lower the cutting means unless you are using a positive mechanical lock.

Measured vibration level for right hand = 1.9 m/s²

Measured vibration level for left hand = 1.5 m/s²

Uncertainty Value (K) = 1.0 m/s²

Measured values were determined according to the procedures outlined in EN ISO 5395:2013.

Measured vibration level = 0.62 m/s²

Uncertainty Value (K) = 0.31 m/s²

Measured values were determined according to the procedures outlined in EN ISO 5395:2013.

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. Shut off the engine and set the parking brake.

2. Clean around the fuel-tank cap and remove the cap.

3. 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.

   Note: This space in the tank allows the gasoline to expand. Do not fill the fuel tank completely full.

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

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.

Figure 18

Figure 19

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.

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

• The parking brake is engaged.

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

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

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

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

Figure 20

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

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

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

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

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

4. Sit on the seat, engage the parking brake, move the blade-control switch (PTO) to the OFF position, and move the motion-control levers to NEUTRAL-LOCK position. Start the engine. While the engine is running, center either motion-control lever and move it forward or reverse; the engine should stop. Repeat for other motion-control lever.

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

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).

Figure 24

Transport-Lock Positions

1. Transport lock
2. LOCK position—The mower deck locks into the transport position.
3. UNLOCK position—The mower deck does not lock into the transport position.

Adjust the height-of-cut from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by moving the clevis pin into different hole locations.

1. Move the transport lock to the LOCK position.

2. Push on the deck-lift pedal with your foot and raise the mower deck to the Transport position (also the 140 mm or 5-1/2 inch 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 30

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

Figure 31

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 32

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

Important: Use the Z Stand on a level surface.

1. Raise the mower deck to the transport position.

2. Remove the bracket pin (Figure 39).

   

   Figure 39

   1. Z Stand
   2. Bracket pin
   3. Bracket
   4. Bottom of slot
   5. Latch

3. Raise the latch.

4. Swing the stand foot out front and slide it toward machine, into the bottom of slot (Figure 39 and Figure 40).

   

   Figure 40

   1. Z Stand (positioned in slot)
   2. Crack in side walk or turf
   3. Latch resting on pivot tab

5. Set the foot of the stand on the ground and rest the latch on the pivot tab (Figure 40).

6. Start the engine and put it at half throttle.

   Note: For best results, place the foot of the stand into the seams in sidewalks or into the turf (Figure 40).

7. Drive the machine onto the stand. Stop when the latch drops over the tab into the locked position (Figure 40).

8. Engage the parking brake and turn off the engine.

9. Chock or block the drive wheels.

   Warning

   Parking brake may not hold machine parked on Z Stand and could cause personal injury or property damage.

   Do not park on the Z Stand unless the wheels are chocked or blocked.

10. Perform the maintenance.

1. Remove the chocks or blocks.

2. Raise the latch to the unlocked position (Figure 41).

   

   Figure 41

   1. Z Stand
   2. Latch
   3. Locked position
   4. Unlocked position

3. Start the engine and place it at half throttle. Disengage the parking brake.

4. Slowly drive backward off the stand.

5. Return the stand to its rest position (Figure 39).

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 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.

Loosen the bottom bolt of the curtain to release the mower-deck curtain and access the top of the mower deck (Figure 42). Tighten the bolt after maintenance to install the curtain.

Figure 42

1. Bolt
2. Curtain

Loosen the 2 front bolts and remove the sheet-metal guard to access the mower belts and spindles (Figure 43). Install the sheet-metal guard and tighten the bolts after maintenance.

Figure 43

1. Sheet-metal guard
2. Bolt

Lubricate the deck-lift pivots.

Figure 44

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. Loosen the bottom bolt holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain.

4. Remove the sheet-metal guard. Refer to Removing the Sheet-Metal Guard.

5. Grease the mower-deck idler-pulley pivot until grease comes out the bottom (Figure 45).

6. Grease the 3 spindle bearings until grease comes out the lower seals (Figure 45).

   

   Figure 45

7. Grease the drive-belt idler arm (Figure 45).

   

   Figure 46

8. 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.

9. Remove the hex plug and thread a grease fitting into the hole.

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

11. Remove the grease fitting from the hole.

12. Install the hex plug and dust cap (Figure 47).

    

    Figure 47

13. Install the sheet-metal guard. Refer to Removing the Sheet-Metal Guard.

14. Tighten the bolt for the mower-deck curtain. Refer to Releasing the Mower-Deck Curtain.

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

   

   Figure 48

   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 SF, SG, SH, SJ, or SL)

Oil 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 50

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 of Spark Plug: NGK^® BPR4ES or equivalent

Air Gap: 0.75 mm (0.030 inch)

Checking the Spark Plug

Important: Never 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 inches).

Figure 57

Installing the Spark Plug

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

Figure 58

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 16).

5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 59).

   

   Figure 59

   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 59).

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 63).

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

3. Install a new fuse (Figure 63).

   

   Figure 63

   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 64).

Figure 64

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

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

2. Drive to an open, flat area 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 65).

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 65).

8. Tighten the stop plate (Figure 65).

   

   Figure 65

   Left control lever shown

   1. Control lever
   2. Bolt
   3. Stop plate

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

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

Figure 66

Check and torque the wheel lug nuts to 122 to 129 N∙m (90 to 95 ft-lb).

Check and ensure that the torque of the slotted nut is 286 to 352 N∙m (211 to 260 ft-lb).

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

Figure 67

1. Slotted nut

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

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

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

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

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

5. Install the dust cap (Figure 68).

   

   Figure 68

   1. Spring washers
   2. Locknut
   3. Dust cap

Some later model year units have been built with clutches that contain a brake shim. When the clutch brake has worn to the point where the clutch no longer engages consistently, you can remove the shim to extend the clutch life.

Figure 69

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

Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 75). This helps ensure adequate cooling, correct engine speed, and reduces the possibility of overheating and mechanical damage to the engine.

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

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

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

   

   Figure 76

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

Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free. This prevents you from accidentally stripping the bolts free of the retainers.

1. Disengage the PTO and set the parking brake.

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

3. Move the seat forward.

4. Wait for the engine and hydraulic system to cool.

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

   

   Figure 77

   1. Hydraulic unit shrouds

6. Over each dipstick, remove the cover and the bolt attached to the cover . Clean around each dipstick and hydraulic unit (Figure 78).

   

   Figure 78

   1. Cover
   2. Bolt

7. Position the seat.

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 79).

   

   Figure 79

   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.

Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free. This prevents you from accidentally stripping the bolts free of the retainers.

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

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

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

4. Loosen the bottom bolt holding the mower-deck curtain to the mower deck. Refer to Releasing the Mower-Deck Curtain.

5. Remove the sheet-metal guard. Refer to Removing the Sheet-Metal Guard

6. Remove the belt covers and the bolts attached to them (Figure 80).

   

   Figure 80

   1. Loosen the bolt.
   2. Remove belt cover.

7. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 81).

8. Remove the belt from the mower deck pulleys.

9. Remove the belt guide on the spring loaded idler arm shown in Figure 81.

10. Remove the existing belt.

11. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 81).

    

    Figure 81

    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

12. Install the belt guide on the idler arm shown in Figure 81.

13. Using the ratchet in the square hole, install the idler spring (Figure 81).

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

14. Install the belt covers and the bolts attached to them (Figure 82).

    

    Figure 82

    1. Position the belt cover.
    2. Slide belt cover under the side catches.
    3. Tighten the bolt.

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.

4. Raise the machine and support it with jack stands (Figure 83).

   

   Figure 83

   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 83).

6. Unhook the idler spring from the frame (Figure 83).

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 83).

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

3. Loosen the bolts and flange nuts installed in the levers (Figure 84).

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 84).

   

   Figure 84

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

   Figure 85

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 86).

   

   Figure 86

   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 87 for mounting options.

Figure 87

Right motion-control lever shown

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

You can adjust the flanged nut to obtain the desired motion-control lever resistance when you move them to the NEUTRAL-LOCK position. See Figure 88 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 88

   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

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 of the moving parts to stop, remove the key, and engage 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) height-of-cut location.

   Note: This locks the deck-lift arms in the lowest position so that when you remove the deck, the stored energy in the deck spring is released.

4. Remove the belt covers.

5. Lift the floor pan and insert a ratchet into the square hole in the deck idler (Figure 104).

6. Rotate the deck idler clockwise and remove the mower belt (Figure 104).

   

   Figure 104

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

7. Remove and retain the hardware on both sides of the deck as shown in Figure 105.

   

   Figure 105

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

8. Raise the deck struts and secure them in the up position.

9. 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 106).

2. Remove the damaged or worn grass deflector (Figure 106).

   

   Figure 106

   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 106.

5. Install the bolt and the nut.

6. Place 1 J-hook end of the spring around the grass deflector (Figure 106).

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