Z Master® 8000 Series Riding Mower

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break-in time for new machines to develop full power and best performance.

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Release the mower deck locking pins on each side (Figure 8).

   

   Figure 8

   1. Deck-lift handle
   2. Pin
   3. Deck-support latch
   4. Rotate the deck-locking pin toward the rear and pull it outward to unlock.
   5. Push the deck-locking pin in and rotate it toward the front to lock.

4. Using the deck-lift handle, lift the deck and latch it in the raised position (latch is located at front center of seat) as shown in Figure 9.

   

   Figure 9

   1. Secure the mower deck in the raised position by securing the mower deck latch onto the hook.
   2. Hook
   3. Deck-lift handle

1. While firmly holding onto deck-lift handle, unhook the mower-deck latch from the machine and slowly lower the mower deck to the ground (Figure 9).

2. Push the deck-locking pins inward and rotate them forward to securely lock the mower deck in the lowered position (Figure 8).

The fill reduction system has been designed to allow you to reduce the amount of clippings collected by varying degrees. The advantages include less frequent emptying of the hopper and the return of nutrients to the soil.

The following are possible configurations:

• Baffles open with standard blades—maximum collection

• Baffles closed with standard blades—partial mulching

• Baffles closed with mulch blades—intermediate mulching

• Mulch plug installed with mulch blades—complete mulching (requires mulch kit)

Adjust the FRS baffles as follows:

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Loosen the bolts attached to the rubber guard (Figure 10).

4. Fold the guard forward.

   

   Figure 10

   1. Bolts
   2. Rubber guard

5. Loosen the locknuts on the rear studs of the FRS baffles.

   

   Figure 11

   1. PTO guard removed for clarity
   2. Loosen the locknuts.

6. Raise the mower deck; refer to Raising the Mower Deck into the Service Position.

7. Remove the bolt and washer at the front of each FRS baffle (Figure 12).

8. Rotate the baffles into the desired position and install the bolt and washer.

   

   Figure 12

   1. Baffles—closed position
   2. Baffles—open position
   3. Bolt
   4. Washer
   5. Baffles

9. Lower the mower deck; refer to Lowering the Mower Deck to the Operating Position.

10. Slightly tighten the locknuts on the rear studs of the FRS baffles.

    Note: The locknuts on the rear studs may be left slightly loose if you anticipate adjusting the baffle frequently.

11. Install the rubber guard using the attached bolts.

To unlatch the seat, remove the bolt and the pin on the left side of the seat (Figure 14).

Figure 14

1. Bolt and pin

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

Engaging the Parking Brake

Park the machine on a level surface.

Figure 17

Disengaging the Parking Brake

Figure 18

The PTO-engagement lever starts and stops the mower blades and blower.

Engaging the PTO-Engagement Lever

Figure 19

Disengaging the PTO-Engagement Lever

Figure 20

You can move the throttle control between FAST and SLOW positions (Figure 21).

Always use the FAST position when engaging the PTO.

Figure 21

Use the choke to start a cold engine.

1. Pull up the choke knob to engage the choke before using the key switch (Figure 22).

2. Push down the choke knob to disengage the choke after the engine has started (Figure 22).

   

   Figure 22

   1. ON position
   2. OFF position

1. Move the speed-control lever to the NEUTRAL position.

2. Engage the parking brake; refer to Engaging the Parking Brake.

3. Move the PTO-engagement lever to the OFF position (Figure 23).

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

5. For EFI machines: Move the choke control to the CLOSED/ON position. On a warm engine, leave the choke in the OPEN/OFF position.

   

   Figure 23

6. Turn the key to the START position (Figure 23). When the engine starts, release the key.

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

   Note: You may need multiple attempts to start the engine the first time after adding fuel to an empty fuel system.

7. If the choke is in the CLOSED/ON position, gradually return choke to the OPEN/OFF position as the engine warms up.

1. Disengage the PTO.

2. Move the speed-control lever to the NEUTRAL position.

3. Engage the parking brake.

4. Place the throttle in the middle position.

5. Let the engine idle for 15 seconds, then turn the key switch to the OFF position and remove the key.

Figure 24

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the FAST position for best performance. Always operate in the full throttle position when mowing.

The cutting height of the mower deck is adjusted from 2.5 to 10.2 cm (1 to 4 inches) in 6.3 mm (1/4 inch) increments.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. While keeping the front frame down, lift the deck on 1 side so that the deck-support latch engages the fixed pin in the front frame (Figure 25).

   

   Figure 25

   1. Deck-lift handle
   2. Pin
   3. Deck-support latch
   4. Rotate the deck-locking pin toward the rear and pull it outward to unlock.
   5. Push the deck-locking pin in and rotate it toward the front to lock.

4. Move the cotter pins on the deck-support pins to the proper hole for the desired height of cut.

5. Lift the deck enough to raise and release the deck-support latch and lower the deck.

6. Repeat this procedure on the other side of the mower deck.

A full hopper is indicated by a buzzer located behind the seat, in the hopper. Empty the hopper when the buzzer sounds to prevent clogging of the blower or the mower deck.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Lift the rear door up and allow it to rest on top of the hopper.

4. Using the handles at the lower front of the hopper, raise the hopper to dump the contents.

5. Lower the hopper and close the hopper door.

Remove the screen by firmly lifting the screen handles (Figure 26).

Pull the screen toward the back to remove it. As needed, gently tap the screen to remove debris.

Note: Excessive buildup on the screen can cause the blower to plug.

Note: In conditions where the screen clogs quickly, you can turn and install the front removable screen panel under the primary screen to allow free air flow from the hopper.

Figure 26

1. Front removable screen can be rotated and stored for wet conditions.
2. Front removable screen
3. Primary screen
4. Handles

The drive-wheel release valves are located on the top, left, front corner of the hydrostatic pumps.

1. Move the speed-control lever to the NEUTRAL position to stop the machine.

2. Disengage the PTO lever, engage the parking brake, shut off the engine, and wait for all moving parts to stop.

3. Tilt the seat up to gain access to the pumps.

4. Rotate both release valves 1 turn counterclockwise to release the drive system.

   Note: This allows the hydraulic fluid to bypass the pump, enabling the wheels to turn.

5. Disengage the parking brake before pushing the machine.

   Note: Do not tow the machine.

6. Rotate the valves clockwise to run the machine.

   Note: Do not overtighten the valves.

Use a heavy-duty trailer or truck to transport the machine. Use a full-width ramp. Ensure that the trailer or truck has all the necessary brakes, lighting, and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you or bystanders avoid injury. Refer to your local ordinances for trailer and tie-down requirements.

Selecting a Trailer

Warning

Loading a machine onto a trailer or truck increases the possibility of tip-over and could cause serious injury or death (Figure 27).

• Use only a full-width ramp; do not use individual ramps for each side of the machine.

• Do not exceed a 15-degree angle between the ramp and the ground or between the ramp and the trailer or truck.

• Ensure that the length of the ramp is at least 4 times as long as the height of the trailer or truck bed to the ground. This ensures that the ramp angle does not exceed 15 degrees on flat ground.

Figure 27

1. Full-width ramp in stowed position
2. Side view of full-width ramp in loading position
3. Not greater than 15 degrees
4. Ramp is at least 4 times as long as the height of the trailer or truck bed to the ground
5. H=height of the trailer or truck bed to the ground
6. Trailer

Grease the machine more often in dirty or dusty conditions.

Grease Type: No. 2 lithium or molybdenum grease

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Clean the grease fittings with a rag.

   Note: 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.

Figure 29

1. Rear caster pivot
2. PTO-belt idler arm
3. Pump-belt idler arm
4. Rear caster hub
5. Drive shaft
6. Front caster wheel hub
7. Deck flip-up pivot
8. Push-arm tubes
9. Front caster pivots

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

2. Raise up the hopper (Figure 30).

   

   Figure 30

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

4. Loosen the bolt holding the air cleaner (Figure 31).

5. Loosen the clamp holding the hose and remove the air cleaner (Figure 31).

   

   Figure 31

   1. Bolt
   2. Clamp

6. Remove the bolts and the plate below the air cleaner.

   

   Figure 32

   1. Plate
   2. Bolts

7. Lubricate the pump-belt idler arm (Figure 32).

8. Install the plate and the air cleaner.

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Lubricate the bronze bushings on the brake-handle pivot with a spray type lubricant or light oil (Figure 33).

   

   Figure 33

   Left Side of Machine Shown

   1. Brake-handle pivot
   2. PTO-handle pivot
   3. Spring-arm pivot
   4. Toggle pivot

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Unlatch the seat latch and tilt the seat up; refer to Unlatching the Seat.

4. Lubricate the bronze bushings on each end of the brake rod shaft with a spray type lubricant or a light oil.

   Note: The bushings are located to the inside of the flange bearings.

5. Lubricate each end of both steering linkage rods with a spray lubricant or a light oil.

1. Park the machine on a level surface, disengage the PTO, and engage the parking brake.

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

3. Remove the guard to access the gearbox (Figure 34)

   

   Figure 34

   1. Gearbox
   2. Guard
   3. Bolt (3)

4. Remove the blades that are attached to the gearbox; refer toRemoving the Blades.

5. Remove the gearbox and drive-shaft assembly from the mower deck. Retain the hardware for use later.

6. Remove the large oil drain plug on the front of each of the 3 gearbox sections and drain the oil (Figure 35).

   

   Figure 35

   1. Small magnetic plugs (front and back)
   2. Large oil drain/fill plug
   3. Small magnetic plug (front only)

7. Remove the small magnetic plugs and wipe away any material accumulated on the plugs.

8. Apply a Teflon^® pipe sealant to all small magnetic plugs and install them into the gearbox.

9. Install the gearbox and drive-shaft assembly to the mower deck.

10. Fill the gearbox with Mobil^® SHC (synthetic) 75W-90 gear lube oil until level with oil drain/fill plug.

    Note: Each of the gearbox sections must be filled separately.

    Note: Keep the mower deck level to the ground when filling the gearbox with oil. Do not fill the gearbox with the mower deck raised in the service position.

11. Apply a Teflon pipe sealant to the 3 large oil plugs and install them into the gearbox.

1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.

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

3. Remove the dust cap and adjust the caster pivots and keep the dust cap off until greasing is done; refer to Greasing the Caster-Wheel Hubs.

4. Remove the hex plug.

5. Thread a grease fitting into the hole.

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

7. Remove the grease fitting from the hole. Install the hex plug and cap.

1. Park the machine on a level surface, disengage the blade-control switch, and engage the parking brake.

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

3. Raise the mower for access.

4. Remove the caster wheel from the caster forks.

5. Remove the seal guards from the wheel hub.

   

   Figure 36

   1. Seal guard
   2. Spacer nut with wrench flats

6. 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.

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

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

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

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

11. If the axle assembly is missing both spacer nuts, 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.

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

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

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

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

16. 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.

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

18. 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: Service the air cleaner more frequently if operating conditions are extremely dusty or sandy.

Type: Champion XC12YC

Air Gap: 0.76 mm (0.03 inch)

Checking the Spark Plug

Important: Do not clean the spark plug(s). Always replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

If you see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

Set the gap to 0.76 mm (0.03 inch).

Figure 44

Installing the Spark Plug

Figure 45

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

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Allow the machine to cool down.

4. Clamp the hose on the fuel tank side of the fuel filter.

5. Replace the fuel filter (Figure 46).

   Note: Ensure that the markings on the filter follow the fuel flow direction.

   

   Figure 46

Note: 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 drain the fuel tank. Ensure that an Authorized Service Dealer drains the fuel tank and services any components of the fuel system.

Adjust all safety switches so that the plunger extends 4.8 mm to 6.4 mm (3/16 inch to 1/4 inch) from the switch body when the plunger is compressed (Figure 49).

Figure 49

1. 4.8 to 6.4 mm (3/16 to 1/4 inch)

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 side behind the seat.

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

3. Install a new fuse.

1. Check and clean corrosion from the battery terminals before jump-starting. Ensure that the connections are tight.

   Caution

   Corrosion or loose connections can cause unwanted electrical voltage spikes at any time during the jump-starting procedure.

   Do not attempt to jump-start the machine with loose or corroded battery terminals, or damage to the engine or EFI may occur.

   Danger

   Jump-starting a weak battery that is cracked or frozen or has a low electrolyte level or an open/shorted battery cell can cause an explosion, resulting in serious personal injury.

   Do not jump-start a weak battery if these conditions exist.

2. Make sure that the booster battery is a good and fully charged lead-acid battery at 12.6 V or greater.

   Note: Use properly sized jumper cables with short lengths to reduce voltage drop between systems. Make sure that the cables are color coded or labeled for the correct polarity.

   Caution

   Connecting the jumper cables incorrectly (wrong polarity) can immediately damage the EFI system.

   Be certain of battery-terminal polarity and jumper-cable polarity when hooking up the batteries.

   Warning

   Batteries contain acid and produce explosive gases.

   • Shield your eyes and face from the batteries at all times.

   • Do not lean over the batteries.

   Note: Ensure that the vent caps are tight and level. Place a damp cloth, if available, over any vent caps on both batteries. Also ensure that the machines do not touch and that both electrical systems are off and at the same rated system voltage. These instructions are for negative ground systems only.

3. Connect the positive (+) cable to the positive (+) terminal of the discharged battery that is wired to the starter or solenoid as shown in Figure 50.

   

   Figure 50

   1. Positive (+) cable on discharged battery
   2. Positive (+) cable on booster battery
   3. Negative (–) cable on the booster battery
   4. Negative (–) cable on the engine block
   5. Booster battery
   6. Discharged battery
   7. Engine block

4. Connect the other end of the positive cable to the positive terminal of the booster battery.

5. Connect the black negative (–) cable to the other terminal (negative) of the booster battery.

6. Make the final connection on the engine block of the stalled machine (not to the negative battery post), away from the battery, and stand back (Figure 51).

   

   Figure 51

   1. Engine block
   2. Negative (–) cable

7. Start the machine and remove the cables in the reverse order of connection (disconnect the negative cable from the engine block first).

Note: The tracking knob is located under the seat.

Note: Rotating this knob allows fine tuning adjustments so that the machine tracks straight with the drive levers in the full forward position.

1. Run the machine at 3/4 speed for at least 5 minutes to bring hydraulic fluid up to operating temperature.

2. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

4. Tilt the seat forward to gain access to the tracking knob.

5. Rotate the knob toward the right to steer right and rotate it toward the left to steer left.

6. Adjust in 1/8 turn increments until the machine tracks straight.

7. Check and ensure that the machine does not creep when in neutral with the parking brakes disengaged (Figure 52).

   

   Figure 52

   1. Tracking knob

Maintain the air pressure in the rear tires at 103 kPa (15 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 does not require air pressure maintenance.

Figure 53

Note: Do not add any type of tire liner or foam fill material to the tires.

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 373 to 475 N∙m (275 to 350 ft-lb).

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Remove the dust cap from the caster and tighten the locknut until the spring washers are flat, then back off 1/4 turn to properly set the pre-load on the bearings (Figure 54 and Figure 55).

   Important: Make sure that the spring washers are installed correctly as shown in Figure 54 and Figure 55.

4. Install the dust cap.

   

   Figure 54

   Front Caster

   1. Spring washers
   2. Locknut
   3. Dust cap
   

   Figure 55

   Rear Caster

   1. Spring washers

Remove any buildup of grass, dirt, or other debris from the oil cooler and the engine screen (Figure 56).

Figure 56

Remove any buildup of grass, dirt, or other debris from the engine screen. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to the engine (Figure 56).

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Remove the fuel-tank mounting nuts and swing out the fuel tank.

4. Keep the oil-cooler free of debris by cleaning the fins with a brush.

5. Swing the fuel tank in and secure it with the mounting nuts.

6. Back the mounting nuts off 1/2 turn to allow for tank expansion.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Remove the air-intake screen and fan housing.

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

5. Install air-intake screen and fan housing.

Make sure that the brake is adjusted properly. Follow this procedure when you remove or replace a brake component.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Release the parking brake.

4. Tilt the seat forward.

5. Check and ensure that there is no slack between the parking-brake handle and the linkage.

6. If an adjustment is necessary, remove the clevis pin and rotate the linkage counterclockwise to lengthen it or clockwise to shorten it.

   

   Figure 57

   1. Parking brake
   2. Rotate yoke
   3. Clevis pin
   4. Speed-control lever
   5. Steering levers

7. Measure the compressed spring length on both vertical spring assemblies.

   Note: The spring should measure between 6 to 7 cm (2.35 to 2.85 inches). If necessary, adjust the nut at the top of the vertical spring assembly to achieve this distance.

   

   Figure 58

   1. Parking brake
   2. Steering lever
   3. Speed-control lever
   4. Vertical spring assembly
   5. Nut
   6. 6 to 7 cm (2.35 to 2.85 inches)

8. Adjust the linkage length with the 2 nuts at the bottom of the vertical spring assembly (Figure 59).

   Note: The linkage should measure 22.7 to 23.3 cm (8.92 to 9.16 inches).

   

   Figure 59

   1. 22.7 to 23.3 cm (8.92 to 9.16 inches)
   2. Nuts

9. Engage and disengage the brakes to check for proper engagement and disengagement. Adjust if necessary.

   Note: When the brakes are disengaged, there should be little to no free play in the brake linkage with no dragging in the brakes.

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. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Tilt the hopper up and check the pump and PTO drive belts for wear, cracking, or contamination.

   Note: The belts are spring tensioned and no adjustment is necessary unless the belts are replaced.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. With the engine off, engage the PTO lever, then remove the hairpin cotter and clevis pin at the bottom of the PTO-brake band.

4. Rotate the brake band upward and out of the way of the belts keeping clear of the belt drive.

5. Disengage the PTO lever.

6. Loosen belt guides A and B (Figure 60).

7. Remove the belts.

8. Route the new belts onto the pulleys as shown in Figure 60.

   

   Figure 60

   1. Idler
   2. Belt guide B
   3. PTO belt
   4. Jackshaft
   5. Engine
   6. Belt guide A
   7. Blower

9. Engage the PTO lever.

10. Rotate the brake band down into the original position.

11. Install the clevis pin and hairpin cotter to secure the brake band.

12. Loosen the jam nuts and adjust the linkage until the top of the idler arm is aligned with the bottom of the notch on the tension arm as shown in Figure 61.

    

    Figure 61

    1. Tension arm
    2. Loosen the jam nuts.
    3. When PTO is engaged, align top of idler arm with bottom of notch on tension arm, as shown.
    4. Idler arm

13. Tighten the jam nuts and disengage the PTO lever.

14. Engage the PTO lever and check the alignment.

15. Check and adjust the belt guides as stated in Adjusting the Belt Guides.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Remove the PTO Belts; refer to Replacing the PTO Belts.

4. Pull the spring idler or remove the spring to relieve the tension of the pump-drive belt.

5. Remove the old belt.

6. Route the new belt onto the sheaves as shown in the decal located on the back of the left drive shield (Figure 62).

   

   Figure 62

   1. Pump-drive belt
   2. Pump
   3. Idler
   4. Pump
   5. Idler
   6. Engine

7. Install the PTO belts; refer to Replacing the PTO Belts.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. With the engine off, engage the PTO lever.

4. Adjust the belt guides as shown in Figure 63.

Figure 63

1. 3 mm (1/8 inch)
2. 11 mm (7/16 inch)
3. 3 mm (1/8 inch) clearance
4. Rotate the wireform guide to center the belts in the guide.
5. 6 mm (1/4 inch)
6. 8 mm (5/16 inch)

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Check the movement of the steering levers as follows:

   • If the levers move slightly forward up to 3 mm (1/8 inch) then no adjustment is necessary.

   • If the levers do not move, then proceed with the following steps:

     1. Flip the seat up or remove the seat-frame assembly (with the seat attached) to obtain a clear view of the steering-control shaft to complete this adjustment.

     2. Place the speed-control lever in the NEUTRAL position.

     3. Release the parking brake.

     4. Slightly adjust the length of the rod by loosening the jam nut and by rotating the rod.

        

        Figure 64

        1. Parking brake
        2. Nut
        3. Steering lever
        4. Speed-control lever
        5. Clevis pin and stop rod

     5. Engage the parking brake and check the steering levers.

     6. Repeat steps 3 through 5 until you achieve up to 3 mm (1/8 inch) movement.

     7. Install the seat frame assembly, if removed in step 1.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Adjust the pivot nut, which is located at the end of the motion-control shaft in front of the right console (Figure 65).

   Note: Set the tension high enough that the speed-control lever position is maintained during operation and loose enough to be moved comfortably.

   

   Figure 65

   1. Pivot nut
   2. Spring-disc washers
   3. Speed-control friction plate
   4. Friction disc
   5. Speed-control friction bracket
   6. Speed-control lever

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Remove the electrical connection from the seat safety switch, located directly in front of the seat-switch assembly.

4. Raise the frame and place on jack stands so that drive wheels can rotate freely.

   Note: You must make the neutral adjustment with the drive wheels turning.

5. Temporarily install a jumper wire across the terminals in the seat safety switch connector of the wire harness.

6. Start the engine.

7. Run the machine at least 5 minutes with the speed-control lever at full forward speed to bring the hydraulic system fluid up to operating temperature.

8. Return the speed-control lever to the NEUTRAL position.

9. To obtain the NEUTRAL position, adjust the left and right pump-control-rod linkages that connect the steering control to the pump-control arms until the wheels stop or creep slightly in reverse (Figure 66).

10. Adjust the left pump linkage by rotating the tracking-adjustment knob.

11. Adjust the right pump linkage by using a wrench to turn the double nuts on the assembly (Figure 66).

    

    Figure 66

    1. Rotate the tracking knob on left side.
    2. Rotate the double nuts on right side.

12. Move the steering levers to the reverse position. While applying slight pressure to the levers, allow the steering levers to return to NEUTRAL.

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

13. Shut off the engine and wait for all moving parts to stop.

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

15. Lower the machine from the jack stands.

Align the PTO-drive pulley for any of the following conditions:

• The blower has been removed or replaced.

• The engine mounting bolts have been loosened or the engine has been moved or replaced.

• The jackshaft mounting bolts have been loosened or the jackshaft has been moved or replaced.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Remove the fuel-tank mounting nuts and swing out the fuel tank.

4. Verify that the blower is installed and tightly secured.

5. Loosen the 4 engine mounting bolts.

6. Unhook the pump-belt tension spring.

7. Loosen the 4 jackshaft mounting bolts.

8. Measuring from the blower pulley as a baseline, move the engine and jackshaft until the rear surface of all 3 pulleys are aligned within 0.8 to 1.6 mm (1/32 inch to 1/16 inch) (Figure 67).

   Note: Use a straight edge to align all 3 surfaces.

   

   Figure 67

   1. Align the 3 pump-drive pulley surfaces shown with this pattern within 0.8 to 1.6 mm (1/32 inch to 1/16 inch).
   2. Align the 3 PTO-drive pulley surfaces shown with this pattern within 0.8 to 1.6 mm (1/32 inch to 1/16 inch).

9. Tighten the 4 engine mounting bolts and 4 jackshaft mounting bolts. Check the alignment after tightening.

10. Install the pump-belt tension spring.

11. Swing the fuel tank in and install the tank mounting nuts.

12. Align the pump-drive pulley; Aligning the Pump-Drive Pulley.

The pump-drive-pulley alignment is necessary for any of the following conditions:

• The engine mounting bolts have been loosened or the engine has been moved or replaced.

• The pump pulleys have been loosened, moved, or replaced.

• The PTO pulley has been aligned; refer to Aligning the PTO-Drive Pulley.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Loosen the set screws on both pump pulleys.

4. Using a straight edge, align each pump pulley with the engine pulley by sliding it along the pump shaft (Figure 67).

5. Tighten the pulley set screws and check the alignment.

Adjust the PTO brake spring only if the blower has been removed or replaced or if the PTO drive idler arm has been disassembled.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Locate the brake spring and thread the 2 jam nuts out to the end of the brake-spring rod (Figure 68).

4. Tighten the jam nuts together at end of the brake-spring rod.

   

   Figure 68

   1. Tighten the jam nuts here.
   2. PTO brake-spring assembly

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Loosen the 6 door hinge nuts (Figure 69).

4. Open the door and place a 3/8 inch (9.5 mm) rubber strip or 3/8 inch (9.5 mm) diameter hose between the hopper and the hopper door (Figure 69).

5. Close the door and push it tight against the hopper.

6. Tighten the hinge hardware.

7. Open the hopper door and remove the rubber strip.

Figure 69

1. Loosen the door hinge nuts—3 per side.
2. Place a piece of 9.5 mm (3/8 inch) rubber on this surface.

1. Slide the mower-deck locking pins in on both sides of the mower deck and rotate them to lock the mower deck in the operating position.

2. Loosen the jam nut and turn the stop screw clockwise until the locking pin is tight and cannot be rotated by hand (Figure 70).

   

   Figure 70

   1. Rotate the stop screw clockwise until the locking pin is tight, then back off 1/2 turn.
   2. Loosen the jam nut.

3. Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut.

4. Test the locking pin to make sure that it slides freely. Adjust if necessary.

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

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

Hydraulic-tank capacity: 5.7 L (6 US qt)

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Allow the engine and the hydraulic system to cool for 10 minutes.

   Note: To get the correct reading, check the hydraulic fluid level when the machine is cool.

4. Raise the seat up; refer to Unlatching the Seat.

5. Clean the area around the dipstick of the hydraulic-system reservoir (Figure 71).

6. Remove the dipstick from the hydraulic reservoir (Figure 71).

7. Wipe the dipstick off and thread the dipstick into the reservoir.

8. Remove the dipstick and look at the end (Figure 71). If the fluid level is at the add mark, slowly pour only enough fluid into the hydraulic reservoir to raise the level to the full line.

   Important: Do not overfill the hydraulic units with fluid, as damage may occur. Do not run the machine with the fluid below the add mark.

9. Install the dipstick.

   

   Figure 71

   1. Full
   2. Add

Note: Use a summer filter when the temperature is 0°C (32°F) and above. Use a winter filter when the temperature is 0°C (32°F) and below.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Carefully clean the area around the filter.

   Important: Ensure that no dirt or contamination enter the hydraulic system.

4. Unscrew and remove the filter and allow the fluid to drain from the reservoir.

   Important: Do not change the hydraulic system fluid (except for what can be drained when changing the filter), unless the fluid has been contaminated or been extremely hot. Changing the hydraulic fluid unnecessarily could damage the hydraulic system by introducing contaminates into the system.

5. Before installing the new filter, fill it with Toro^® HYPR-OIL^™ 500 hydraulic fluid and apply a thin coat of fluid on the surface of the rubber seal.

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

7. Fill the reservoir as stated in Checking the Hydraulic Fluid.

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

9. Start the engine and move the throttle control to the FULL-THROTTLE position.

10. Move the speed-control levers to the full-speed position and run the machine for several minutes.

11. Shut off the machine and check the fluid level.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the PTO, and engage the parking brake.

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

3. Raise the seat.

4. Clean the debris and grass from the hydraulic pumps.

5. Lower the seat.

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.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Check the tire pressure in the drive tires; refer to Checking the Tire Pressure.

4. Verify that all hairpin cotters are in the 7.62 cm (3 inch) mower-deck-height holes with the spacers under the hairpin cotters (Figure 77).

   

   Figure 77

   Right Side Shown

   1. Hairpin cotter
   2. Spacer
   3. Mower-deck support pin

5. Shorten or lengthen each mower deck support pin to obtain blade tip height of 7.62 cm (3 inches) at the front of the deck and 8.26 cm (3 1/4 inches) at the rear of the deck (Figure 77).

   Note: The front pins are thread into the mower deck and have a jam nut. The rear pins have a rod end threaded into them with a jam nut.

Important: Do not transport this machine without an approved Toro front mount attachment.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Raise mower deck up and latch with deck-locking pins. Refer to Raising the Mower Deck into the Service Position.

4. Remove the hairpin cotters and washers at the top of the deck-lift-assist spring on each side of the machine (Figure 78).

   

   Figure 78

   1. Spring anchor pin under console
   2. Secure springs with a washer and hairpin cotter
   3. Slide the spring onto the spring-anchor pin

5. Remove the spring from the spring anchor. Repeat for other side of the machine.

6. Unlatch the mower deck from the raised position and slowly lower the mower deck to ground; refer to Lowering the Mower Deck to the Operating Position.

   Note: The mower deck becomes heavier when you remove the springs from the anchors. Lower the mower deck carefully.

7. Remove the lynch pins at the front of the push arms on both sides of the machine (Figure 79).

   

   Figure 79

   1. Push arm
   2. Lynch pin
   3. Push-arm tube

8. Loosen the bolts attached to the rubber guard (Figure 80).

   

   Figure 80

   1. Bolts
   2. Rubber guard

9. Unlatch the seat and disconnect the drive shaft using the quick coupler at the jackshaft (Figure 81). Refer to Unlatching the Seat

   

   Figure 81

   1. Jackshaft
   2. Drive shaft

10. Pull the mower deck forward to remove it from the machine.

Important: Do not transport the machine without an approved Toro front mount attachment.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Roll the mower deck up to the machine with the discharge tube down, making sure that the deck springs are located above the drive wheel and below the console on each side.

4. Unlatch the seat and tilt the seat forward.

5. Install the drive shaft onto the jackshaft (Figure 81).

6. Align the mower-deck push-arm tubes to the machine push-arms and push the mower deck rearward.

7. Secure the push arms with the lynch pins on the left and right sides of the machine (Figure 79).

8. Align the upper portion of the rubber guard and secure it with the attached bolts (Figure 80).

9. Release the mower-deck-locking pins on each side, raise the mower deck to the service position and secure the deck latch onto the hook. Refer to Raising the Mower Deck into the Service Position.

10. Install the springs onto the spring anchor pins under the left and right consoles and secure it with a washer and hairpin cotter (Figure 78).

11. Unlatch the mower deck from the raised position, slowly lower the mower deck to ground, and lock the deck-locking pins on each side. Refer to Lowering the Mower Deck to the Operating Position.

1. Slide the mower-deck locking pins in on both sides and rotate to lock the deck in the operating position.

2. Loosen the jam nut and turn the stop screw clockwise until the locking pin is tight and cannot be rotated by hand (Figure 82).

   

   Figure 82

   1. Rotate the stop screw clockwise until locking pin is tight, then back off 1/2 turn.
   2. Loosen the jam nut

3. Loosen the stop screw counter clockwise 1/2 turn and tighten the jam nut.

4. Test the locking pin to make sure it slides freely. Adjust it if necessary.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Lift the mower deck and secure it in the raised position. Refer to Raising the Mower Deck into the Service Position.

4. Clean any grass buildup under the mower deck.

5. Lower the mower deck to the operating position. Refer to Lowering the Mower Deck to the Operating Position.

1. Park the machine on a level surface, move the speed-control lever to the NEUTRAL position, disengage the blade-control switch (PTO), and engage the parking brake.

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

3. Clean off any oil, debris, or grass buildup on the machine, especially around the fuel tank, engine, and exhaust area.

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