Z Master® Professional 5000 Series Riding Mower

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

  Note: 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.

  Note: Use only accessories and attachments approved by the manufacturer.

• Wear appropriate clothing, including eye protection, substantial, slip-resistant shoes, 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-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.

• Only operate 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 from the operating position only.

• 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 all interlocks are attached, adjusted properly, and functioning properly.

• Do not 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 the parking brake (if provided), shut off the engine before leaving the operator's position for any reason, including emptying the catchers or unclogging the chute.

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

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

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

• Keep pets and bystanders away from an operating machine.

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

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

• Do not operate the mower under the influence of alcohol or drugs.

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

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

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

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

• Use only an approved fuel container.

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

• Allow the engine to cool before fueling.

• Do not refuel 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 your clothing, change your clothing immediately.

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

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

• 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 spillage.

• Let the engine cool before storing.

• Do not store fuel near flames or drain indoors.

• Do not allow untrained personnel to service 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. Reconnect the positive 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.

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

Figure 8

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. Park the machine on level ground.

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

3. Clean around the fuel-tank cap and remove it. Add regular unleaded 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 (Figure 12).

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

   

   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-LOCK position.

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

4. Move the blade-control switch (PTO) to the OFF position (Figure 18).

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

   

   Figure 18

6. Turn the ignition key to the Start position (Figure 19).

   Note: 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 19

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

Figure 20

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

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

• The parking brake is engaged.

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

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

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

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

Figure 21

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

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

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

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

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

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

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

Note: The engine will shut off if you move the traction-control levers with the parking brake engaged.

To stop the machine, 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 23).

   

   Figure 23

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

2. To go backward, slowly pull the motion-control levers rearward (Figure 24).

   

   Figure 24

The transport lock has 2 positions, which are used with the deck-lift pedal. There is a LOCK position and an UNLOCK position for the transport position. Use the transport lock with the deck-lift pedal (Figure 25).

Figure 25

Transport-Lock Positions

1. Transport lock
2. LOCK position—release the lock from the locked position
3. UNLOCK position—does not lock the mower deck into transport position

The height-of-cut is adjusted from 25 to 140 mm (1 to 5-1/2 inches) in 6 mm (1/4 inch) increments by 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 140 mm (5-1/2 inches) cutting height position) as shown in Figure 26.

3. To adjust, rotate the pin 90 degrees and remove the pin from the height-of-cut bracket (Figure 26).

4. Select a hole in the height-of-cut bracket corresponding to the height-of-cut desired, and insert the pin (Figure 26).

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

   

   Figure 26

   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 as follows:

• Short, light grass mowing conditions

• Dry conditions

• Smaller grass clippings

• Propels grass clippings farther away from the mower

  

  Figure 31

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

Figure 32

This is the full-open position. Use this position is as follows:

• Tall, dense grass mowing conditions

• 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 33

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 setting so low as to totally surround the mower by 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 grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 15 cm (6 inches) tall, cut the lawn twice to ensure an acceptable quality of cut.

It is best to cut only about 1/3 of the grass blade. Do not cut more than that unless the 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.

Grass grows at different rates at different times. So to maintain the same cutting height, 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 you 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, cutting quality will eventually become unsatisfactory.

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

Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: No. 2 lithium or molybdenum grease

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

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

3. Clean the grease fittings with a rag.

   Note: Make sure to scrape any paint off the front of the fitting(s).

4. Connect a grease gun to the fitting.

5. Pump grease into the fittings until grease begins to ooze out of the bearings.

6. Wipe up any excess grease.

Adding Light Oil or Spray Lubrication

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

Lubricate the deck-lift pivots.

Figure 41

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

   

   Figure 45

   1. Seal guard
   2. Spacer nut with wrench flats

2. Raise the mower for access.

3. Remove the caster wheel from the caster forks.

4. Remove the seal guards from the wheel hub.

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

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

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

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

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

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

   Note: Replace the seals.

10. If the axle assembly has had both spacer nuts removed (or broken loose), apply 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.

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

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

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

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

15. Torque the nut to 8 to 9 N-m (75 to 80 in-lb), loosen, then torque to 2 to 3 N-m (20 to 25 in-lb).

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

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

17. 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 adhesive.

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)

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

Viscosity: See the table below.

Figure 48

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

Make sure that the air gap between the center and side electrodes is correct before installing the spark plugs. Use a spark-plug wrench for removing and installing the spark plugs and a gapping tool/feeler gauge to check and adjust the air gap. Install new spark plugs if necessary.

Type : Champion^® XC12YC, Champion^® Platinum 3071 or equivalent

Air Gap: 0.76 mm (0.030 inch)

Checking the Spark Plugs

Important: Replace the spark plugs when they have a black coating, worn electrodes, an oily film, cracks, or if 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 that the air cleaner is dirty.

Set the gap to 0.76 mm (0.030 inch).

Figure 55

Installing the Spark Plugs

Tighten the spark plugs to 27 N-m (20 ft-lb).

Figure 56

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

2. Wait for the muffler to cool.

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

4. If the screen is plugged, remove the arrester and shake loose particles out of the arrester, and clean the screen with a wire brush (soak in solvent if necessary).

5. Install the arrester on the exhaust outlet.

This machine contains an electronic fuel injection (EFI) system. It controls the fuel flow under different operating conditions.

The electronic control unit (ECU) continuously monitors the operation of the EFI system.

If a problem or fault within the system is detected, the malfunction-indicator light (MIL) is illuminated. The MIL is the red light located in the right console panel.

Once the MIL illuminates, initial trouble shooting checks should be made. Refer to the MIL section under .

If these checks do not correct the problem, further diagnosis and servicing by an Authorized Service Dealer is necessary.

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

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

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

3. Allow the machine to cool down.

4. Close the fuel-shutoff valve under the seat (Figure 57).

   

   Figure 57

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

5. Squeeze the ends of the hose clamps together and slide them away from the filter (Figure 57).

6. Remove the filter from the fuel lines.

7. Install a new filter and move the hose clamps close to the filter (Figure 57).

8. Open the fuel-shutoff valve.

Important: Install the fuel-line hoses and secure them with plastic ties the same as they were originally installed at the factory to keep the fuel line away from components that could cause fuel line damage.

Do not attempt to service the high-pressure fuel filter. The high-pressure filter is integrated within the fuel pump module. The fuel filter and other components inside the fuel pump module are not serviceable. Do not attempt to open the fuel-pump module.

Ensure that an Authorized Service Dealer replaces the fuel-pump module with the high-pressure fuel filter.

Do not attempt to drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank.

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 console next to the seat (Figure 61).

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

3. Install a new fuse (Figure 61).

   

   Figure 61

   1. Optional accesory—15 A
   2. Charge—25 A
   3. PTO—10 A
   4. Main—25 A
   5. Console

Visually inspect seat belt for wear, cuts, and proper operation of retractor and buckle. Replace the seat belt before operating the machine if the belt 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. You may need to push the upper hoop of the roll bar forward or pull it rearward to fully engage both knobs (Figure 62).

Figure 62

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

Refer to Adjusting the Control-Handle Position.

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 63

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 64

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 65).

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 65).

   Important: Ensure that the spring washers are installed correctly as shown in Figure 65.

5. Install the dust cap (Figure 65).

   

   Figure 65

   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 life of the clutch.

Figure 66

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

Remove any buildup of grass, dirt, or other debris from the oil cooler (Figure 72).

Figure 72

Before each use, remove any buildup of grass, dirt, or other debris from the engine screen. This help ensures adequate cooling, correct the engine speed, and reduces the possibility of overheating and mechanical damage to the engine (Figure 73).

1. Disengage the PTO and set the parking brake.

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

3. Remove the air-intake screen, the recoil starter, and the fan housing (Figure 73).

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

5. Install the air-intake screen, the recoil starter, and the fan housing (Figure 73).

   

   Figure 73

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

1. Disengage the PTO and set the parking brake.

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

3. Move the seat forward.

4. Clean the debris and grass from the hydraulic-unit shrouds (Figure 74).

5. Position the seat.

   

   Figure 74

   1. Hydraulic-unit shrouds

Note: Follow this procedure after you remove or replace a brake component.

1. Move 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 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 stands 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 to see if there is a visible gap between the L-bracket and the linkage stop (Figure 75).

   

   Figure 75

   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, do the following steps:

    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 obtain 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.

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

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 inches) height-of-cut position.

4. Remove the belt covers (Figure 76).

   

   Figure 76

5. Use a ratchet in the square hole in the idler arm to remove tension on the idler spring (Figure 77).

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

7. Remove the belt guide on the spring-loaded idler arm (Figure 77).

8. Remove the existing belt.

9. Install the new belt around the mower pulleys and the clutch pulley under the engine (Figure 77).

   

   Figure 77

   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 77).

11. Using the ratchet in the square hole, install the idler spring (Figure 77).

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

12. Install the belt covers (Figure 78).

    

    Figure 78

1. Disengage the PTO and set the parking brake.

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

3. Remove the mower belt; refer to Replacing the Mower Belt.

4. Raise the machine and support it with jack stands (Figure 79).

   

   Figure 79

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

5. Use a ratchet in the square hole in the idler arm to remove the idler spring (Figure 79).

6. Unhook the idler spring from the frame (Figure 79).

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 79).

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-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 80).

4. Align the levers in the front-to-rear position by bringing the levers together to the NEUTRAL position, and slide them until they are aligned, then tighten the bolts (Figure 81).

   

   Figure 80

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

   Figure 81

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

6. Repeat to adjust the control levers.

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.

2. Lower deck to the ground.

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

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

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

   Note: The switch is a part of the seat assembly.

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

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

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

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

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

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

9. Adjust the pump control rod lengths by rotating the double nuts on the rod in the appropriate direction until the wheels slightly creep in reverse (Figure 82).

   

   Figure 82

   1. Double nuts

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

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

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

12. Remove the jack stands.

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

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

You can adjust the top damper mounting bolt to obtain a more desired motion-control lever resistance. See Figure 83 for mounting options.

Figure 83

Right Control Shown

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

You can adjust the flanged nut to obtain a more desired motion-control lever resistance when moving it to the NEUTRAL-LOCK position. See Figure 84 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 84

   1. Flanged nut
   2. Jam nut

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

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

Each Hydraulic System Fluid 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, you may want to keep extra blades on hand.

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

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

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

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

   Note: This locks the deck-lift arms in the lowest position when you remove the deck and release the stored energy in the deck spring.

4. Remove the belt covers.

5. Lift up the floor pan and insert a ratchet into the square hole in the deck idler (Figure 99).

6. Rotate the deck idler clockwise and remove the mower belt (Figure 99).

   

   Figure 99

   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 (Figure 100).

   

   Figure 100

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

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

9. Slide the deck out to the right side of the machine.

1. Remove the locknut, the bolt, the spring, and the spacer holding the deflector to the pivot brackets (Figure 101).

2. Remove the damaged or worn grass deflector (Figure 101).

   

   Figure 101

   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: Ensure that 1 J-hook end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 101.

5. Install the bolt and the nut.

6. Place 1 J-hook end of the spring around the grass deflector (Figure 101).

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

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

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

3. Raise the mower to the transport position.

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