Z Master® Professional 2000 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.

The seat can move forward and backward (Figure 13). Position the seat where you have the best control of the machine and are most comfortable.

Figure 13

Seat for machines with MyRide shown.

The seat is adjustable to provide a smooth and comfortable ride. Position the seat where you are most comfortable.

To adjust it, turn the knob in front either direction to provide the best comfort (Figure 14).

Figure 14

1. Seat-suspension knob

The MyRide™ suspension system adjusts to provide a smooth and comfortable ride. You can adjust the rear 2-shock assemblies to quickly and easily change the suspension system. Position the suspension system where you are most comfortable.

The slots for the rear-shock assemblies have detent positions for reference. You can position the rear-shock assemblies anywhere in the slot, not just in the detent positions. The following graphic shows the position for a soft or firm ride and the different detent positions (Figure 15).

Figure 15

1. Firmest position
2. Softest position
3. Detents in the slots

Note: Ensure that the left and right rear-shock assemblies are always adjusted to the same positions.

Adjust the rear-shock assemblies (Figure 16).

Figure 16

Use only Toro approved attachments and accessories.

If you add more than 1 accessory mount kit (i.e., bucket kit or universal mount kit) to both of the locations shown in Figure 17, add a front weight kit. Contact an Authorized Service Dealer for the front weight kit.

Figure 17

1. Add a front weight kit when accessory mount kits are installed at both of these positions.

Use the mower deck as a step to get into the operator’s position (Figure 20).

Figure 20

1. Step here.

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 21

Disengaging the Parking Brake

Figure 22

The blade-control switch (PTO) starts and stops the mower blades and any powered attachments.

Engaging the Blade-Control Switch (PTO)

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

Figure 23

Disengaging the Blade-Control Switch (PTO)

Figure 24

You can move the throttle control between FAST and SLOW positions (Figure 25).

Always use the FAST position when engaging the PTO.

Figure 25

Use the choke to start a cold engine.

1. Pull up the choke knob to engage the choke before using the key switch (Figure 26).

2. Push down the choke knob to disengage the choke after the engine has started (Figure 26).

   

   Figure 26

   1. ON position
   2. OFF position

Note: A warm or hot engine may not require choking.

Important: Do not engage the starter for more than 5 seconds at a time. Engaging the starter motor for more than 5 seconds can damage the starter motor. If the engine fails to start, wait 10 seconds before operating the engine starter again.

Figure 27

Note: Refer to Figure 43 to determine which engine you have.

Shutting Off Kawasaki Engines

Let the engine idle at slow throttle for 60 seconds before turning the switch off.

Figure 28

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

Shutting Off Toro Engines

Note: Ensure the throttle is in the FAST position before shutting off the engine.

Figure 29

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

The drive wheels turn independently, powered by hydraulic motors on each axle. You can turn 1 side in reverse while you turn the other forward, causing the machine to spin rather than turn. This greatly improves the machine maneuverability but may require some time for you to adapt to how it moves.

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 mower has a hinged grass deflector that disperses clippings to the side and down toward the turf.

Whenever you change the height of cut, adjust the height of the anti-scalp rollers.

Note: Adjust the anti-scalp rollers so that the rollers do not touch the ground in normal, flat mowing areas.

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. Adjust the anti-scalp rollers as shown in Figure 35.

   

   Figure 35

   1. Flange nut
   2. Bolt
   3. Bushing
   4. Anti-scalp roller
   5. Spacer

Close the fuel-shutoff valve for transport, maintenance, and storage (Figure 36).

Ensure that the fuel-shutoff valve is open when starting the engine.

Figure 36

1. ON position
2. OFF position

The drive-wheel release valves are located on the left and right sides underneath the engine deck.

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. Locate the bypass levers behind the seat, down on the left and right side of the frame.

4. To push the machine, move both bypass knobs rearward and lock them into place (Figure 37).

5. Disengage the parking brake before pushing the machine.

   

   Figure 37

   1. Front of the machine
   2. Rotate bypass release knob counterclockwise to loosen.
   3. Lever position for operating the machine
   4. Pull the lever in this direction to push the machine.
   5. Lever position for pushing the machine
   6. Rotate the bypass-release knob clockwise to tighten.
   7. Engine
   8. Release lever

6. To run the machine, move the bypass knobs to the FORWARD position and lock them into place (Figure 37).

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 38).

• 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 38

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 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. Clean the grease fittings with a rag.

   Note: Scrape any paint off the front of the fitting(s).

4. Grease the pump idler-pulley pivot with 1 or 2 pumps of grease (Figure 41).

5. Grease the front caster axles (Figure 41).

   

   Figure 41

   1. Pump-idler pivot
   2. Caster axle

6. Wipe up any excess grease.

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 42

   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.

Use the following graphic to identify the engine you have and proceed to the section listed below for service (Figure 43).

Figure 43

1. Kawasaki engine
2. Toro engine

• For Kawasaki engine maintenance, refer to Servicing a Kawasaki® Engine.

• For Toro engine maintenance, refer to Servicing a Toro Engine.

This section is only for machines with Kawasaki engines. If your engine looks like the one shown in Figure 44, you have a Kawasaki engine.

Important: Refer to your engine owner’s manual for additional maintenance procedures.

Figure 44

Servicing the Engine Oil

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	For Kawasaki engines—check the engine-oil level.
Every 100 hours	For Kawasaki engines—change the engine oil(more often in dirty or dusty conditions).
Every 200 hours	For Kawasaki engines—change the engine-oil filter(more often in dirty or dusty conditions).

Engine-Oil Specifications

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

Crankcase Capacity: 1.8 L (61 fl oz) without the oil filter; 2.1 L (71 fl oz) with the oil filter

Viscosity: See the table below.

Figure 46

Note: Although 10W-40 engine oil is recommended for most conditions, you may need to change oil viscosity to accommodate atmospheric conditions. Using 20W-50 engine oil in higher ambient temperatures can reduce oil consumption.

Checking the Engine-Oil Level

Note: Check the oil when the engine is cold.

Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.

1. Park the machine on a level surface, 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.

   Note: Ensure that the engine is cool so that the oil has had time to drain into the sump.

3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 47).

Figure 47

Changing the Engine Oil

Note: Dispose of the used oil at a recycling center.

1. Start the engine and let it run for 5 minutes.

   Note: This warms the oil so that it drains better.

2. Park the machine so that the drain side is slightly lower than the opposite side to ensure that the oil drains completely.

3. Disengage the blade-control switch (PTO) and engage the parking brake.

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

5. Drain the oil from the engine (Figure 48).

   

   Figure 48

6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 49).

   

   Figure 49

7. Start the engine and drive to a flat area.

8. Check the oil level again.

Changing the Engine-Oil Filter

1. Drain the oil from the engine; refer to Changing the Engine Oil.

2. Change the engine-oil filter (Figure 50).

   

   Figure 50

   Note: Ensure that the oil-filter gasket touches the engine, and then turn the oil filter an extra 3/4 turn.

3. Fill the crankcase with the proper type of new oil; refer to Engine-Oil Specifications.

Servicing the Spark Plug(s)

Maintenance Service Interval	Maintenance Procedure
Every 100 hours	For Kawasaki engines—replace or clean and gap the spark plug.

Ensure that 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 and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type of Spark Plug: NGK^® BPR4ES or equivalent

Air Gap: 0.75 mm (0.03 inch)

Removing the Spark Plug(s)

1. Park the machine on a level surface, 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 the area around the base of the plug to keep dirt and debris out of the engine.

4. Locate and remove the spark plug(s) as shown in Figure 51.

   

   Figure 51

Checking the Spark Plug(s)

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 0.75 mm (0.03 inch).

Figure 52

Installing the Spark Plug(s)

Figure 53

This section is only for machines with Toro engines. If your engine looks like the one shown in Figure 54, you have a Toro engine.

Figure 54

Servicing the Engine Oil

Maintenance Service Interval	Maintenance Procedure
After the first 5 hours	For Toro engines—change the engine oil and filter.
Before each use or daily	For Toro engines—check the engine-oil level.

Engine-Oil Specifications

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

Crankcase Capacity: 2.4 L (81 fl oz) with oil filter

Viscosity: See the table below.

Figure 56

Checking the Engine-Oil Level

Note: Check the oil when the engine is cold.

Important: If you overfill or underfill the engine crankcase with oil and run the engine, you may damage the engine.

1. Park the machine on a level surface, 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.

   Note: Ensure that the engine is cool so that the oil has had time to drain into the sump.

3. To keep dirt, grass clippings, etc., out of the engine, clean the area around the oil-fill cap and dipstick before removing it (Figure 47).

Figure 57

Changing the Engine Oil and Oil Filter

1. Park the machine on a level surface to ensure that the oil drains completely.

2. 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. Drain the oil from the engine.

   

   Figure 58

5. Change the engine-oil filter (Figure 59).

   Note: Ensure that the oil-filter gasket touches the engine and then turn the filter an extra 3/4 turn.

   

   Figure 59

6. Slowly pour approximately 80% of the specified oil into the filler tube and slowly add the additional oil to bring it to the Full mark (Figure 60).

   

   Figure 60

7. Dispose of the used oil at a recycling center.

Servicing the Spark Plug(s)

Maintenance Service Interval	Maintenance Procedure
Every 200 hours	For Toro engines—replace the spark plug(s).

Ensure that 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 and a gapping tool or feeler gauge to check and adjust the air gap. Install a new spark plug if necessary.

Type: Champion^® RN9YC or NGK^® BPR6ES

Air gap: 0.76 mm (0.03 inch)

Removing the Spark Plug(s)

1. Park the machine on a level surface, 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 the area around the base of the plug to keep dirt and debris out of the engine.

4. Locate and remove the spark plug(s) as shown in Figure 62.

   

   Figure 61

Checking the Spark Plug(s)

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 62

Installing the Spark Plug(s)

Figure 63

To ensure proper cooling, ensure that the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times.

Important: Operating the engine with a blocked grass screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating.

Before each use remove any buildup of grass, dirt, or other debris from the engine screen, engine exhaust, and the area around the engine. This helps ensure adequate cooling and correct engine speed and reduces the possibility of overheating and mechanical damage to the engine.

1. Park the machine on a level surface, 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 air filter from the engine.

4. Remove the engine shroud.

5. To prevent debris entering the air intake, install the air filter to the filter base.

6. Clean debris and grass from the parts.

7. Remove the air filter and install the engine shroud.

8. Install the air filter.

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. Wait for the muffler to cool.

4. If you see any breaks in the screen or welds, replace the arrester.

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

6. Install the arrester on the exhaust outlet.

1. Park the machine on a level surface, 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 filter from the vent hose.

4. Insert a new filter into the end of the vent hose.

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.

The fuel filter is located near the engine on the left front of the engine.

1. Park the machine on a level surface, 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. Close the fuel-shutoff valve under the seat (Figure 64).

   

   Figure 64

5. Open the fuel-shutoff valve.

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 and circuit for a malfunction or short.

The fuses are located on the right console next to the seat (Figure 68).

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

2. Install a new fuse (Figure 68).

   

   Figure 68

   1. Fuse cover
   2. Fuse holder
   3. Fuel-shutoff valve

Inspect the seat belt for wear, cuts, and proper operation of the retractor and buckle. Replace the seat belt if it is damaged.

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, insert a 3/16 inch hex wrench through the access hole in the right front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever (Figure 69).

7. If the machine tracks to the left, insert a 3/16 inch hex wrench through the access hole in the right front cover panel and rotate the tracking screw clockwise or counterclockwise to adjust the travel of the lever (Figure 69).

8. Drive the machine and check the full forward tracking.

9. Repeat the adjustment until the desired tracking is obtained.

   

   Figure 69

   Right control lever shown

   1. Access hole on front cover panel
   2. Tracking screw

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

Figure 70

Check and torque the wheel lug nuts to 122 to 136 N∙m (90 to 100 ft-lb).

Note: Perform this procedure whenever you remove or replace a brake component.

1. Park the machine on a level surface, 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. Set up the machine to be pushed by hand. Refer to Using the Drive-Wheel Release Valves.

4. Raise the back of the machine up and support the machine with jack stands.

   Warning

   Relying solely on mechanical or hydraulic jacks to support a raised machine for service or maintenance could be dangerous because the jacks may not provide enough support or may malfunction, allowing the machine to fall and possibly cause serious injury.

   Do not rely solely on mechanical or hydraulic jacks for support. Use adequate jack stands or equivalent support.

5. Engage and disengage the parking brake and check each drive tire to ensure that each brake engages and disengages.

6. If an adjustment is necessary, disengage the parking brake. Remove the cotter pin from the brake linkage shaft (Figure 71).

   

   Figure 71

   1. Cotter pin
   2. Parking brake
   3. Brake linkage shaft

7. Check both spring lengths as shown in Figure 72. If an adjustment is necessary, turn the top nut clockwise to shorten the spring and counterclockwise to lengthen it.

   

   Figure 72

   1. Top nut
   2. Spring
   3. 44 mm (1-3/4 inches)

8. Push the parking brake lever all the way forward and down.

9. Rotate the brake-linkage shaft until the end aligns with the hole in the lever.

   • Shorten the linkage by turning it clockwise.

   • Lengthen the linkage by turning it counterclockwise.

10. Insert the brake-linkage shaft into the parking-brake hole and secure with the cotter pin. Repeat step 5 and adjust if necessary.

11. When adjustment is complete, remove the jack stands or equivalent support and lower the machine.

12. Place the machine into the OPERATING position. Refer to Using the Drive-Wheel Release Valves.

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

4. Remove the belt covers (Figure 73).

   

   Figure 73

5. Remove the spring tension from the spring-loaded idler pulley; refer to Figure 75.

   Note: Use the spring removal tool (Toro Part No. 92-5771) to remove the spring from the mower-deck post (Figure 75).

6. Remove the belt from the mower-deck pulleys and the clutch pulley.

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

   

   Figure 74

   1. Clutch pulley
   2. Mower belt
   3. Spring-loaded idler pulley
   4. Spring
   

   Figure 75

   1. Spring-removal tool (Toro Part No. 92-5771)
   2. Idler spring
   3. Mower-deck post
   4. Idler arm
   5. Mower belt

8. Install the idler spring (Figure 74).

   Note: Seat the spring ends in the anchor grooves.

9. Install the belt covers (Figure 76).

   

   Figure 76

1. Park the machine on a level surface, 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 mower belt; refer to Replacing the Mower Belt.

4. Raise the machine and support it with jack stands (Figure 78).

5. Remove the clutch stop (Figure 77).

   

   Figure 77

   1. Clutch stop

6. Remove the idler spring from the post (Figure 78).

7. Remove the existing belt from the hydraulic-pump-drive pulleys and the engine pulley.

8. Install the new belt around the engine pulley and the 2 hydraulic-pump pulleys (Figure 78).

   

   Figure 78

   1. Idler pulley
   2. Idler-spring post
   3. Engine pulley
   4. Pump-drive belt
   5. Right hydraulic-pump pulley
   6. Left hydraulic-pump pulley

9. Install the clutch stop (Figure 77).

10. Install the mower belt; refer to Belt Maintenance.

If the ends of the levers hit against each other, refer to Adjusting the Motion-Control Linkage.

Located on either side of the machine, below the seat, are the pump-control linkages. Rotating the end nut with a 1/2-inch deep socket wrench allows fine tuning adjustments so that the machine does not move in neutral. Any adjustments should be made for neutral positioning only.

1. Park the machine on a level surface, 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. Push the deck-lift pedal, remove the height-of-cut pin, and lower the mower deck to the ground

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

5. 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.

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

7. Start the engine, run it at full throttle, and disengage the parking brake.

   Note: Before starting the engine, ensure that the parking brake is engaged and that the motion-control levers are out. You do not have to be in the seat.

8. Run the machine 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 must be in neutral while you are making any adjustments.

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

10. Check and ensure that the control-plate tabs touch the return-to-neutral plates on the hydraulic units.

11. Adjust the pump-control-rod lengths by rotating the nut in the appropriate direction until the wheels slightly creep in reverse (Figure 81).

    

    Figure 81

    1. Nut
    2. Stationary plate
    3. Control plate
    4. Return-to-neutral plate
    5. Tabs touching return to neutral plate

12. 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 should stop turning or slightly creep in reverse.

    Note: You may need to remove the motion-control cover to gain access.

13. Shut off the machine.

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

15. Remove the jack stands.

16. Raise the mower deck and install the height-of-cut pin.

17. Check and ensure that the machine does not creep in neutral with the parking brake disengaged.

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

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

Hydraulic System Capacity (with filters removed): 4.45 L (150 fl oz)

1. Allow the hydraulic fluid to cool down. Check the oil level when the fluid is cold.

2. Check expansion reservoir and if necessary add Toro^® HYPR-OIL^™ 500 hydraulic fluid to the FULL COLD line.

   

   Figure 82

   1. Engine
   2. Expansion tank

To replace the hydraulic fluid, the filters need to be removed. Replace both at the same time; refer to Hydraulic Fluid Specifications for fluid specifications.

Purge any air in the system after you install the new filters and add fluid. Refer to Bleeding the Hydraulic System. Repeat the bleeding process until the fluid remains at the FULL COLD line in the reservoir after purging. Failure to properly perform this procedure can result in irreparable damage to the transaxle drive system.

Installing the Hydraulic-System Filters

1. Apply a thin coat of hydraulic fluid on the surface of the rubber seal of each filter.

2. Turn the filter clockwise until the rubber seal contacts the filter adapter, then tighten the filter an additional 3/4 to 1 full turn.

3. Repeat for the opposite filter.

4. Install the filter guards over each filter that you previously removed.

5. Use the 3 screws to secure the filter guards.

6. Verify that the vent plugs are removed before adding the fluid.

7. Slowly pour the specified fluid through the expansion reservoir until fluid comes out of 1 of the vent-plug holes.

8. Install the vent plug.

9. Torque the plug to 20 N∙m (15 ft-lb).

10. Continue to add fluid through the expansion reservoir until fluid comes out of the remaining vent-plug hole on the second transmission.

11. Install the opposite vent plug.

12. Torque the plug to 20 N∙m (15 ft-lb).

13. Continue to add fluid through the expansion reservoir until it reaches the FULL COLD line on the expansion reservoir.

14. Proceed to Bleeding the Hydraulic System.

    Important: Failure to perform the Bleeding the Hydraulic System procedure after changing hydraulic filters and fluid can result in irreparable damage to the transaxle drive system.

Figure 84

1. 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.

   

   Figure 85

   1. Jacking points

2. Start the engine, move the throttle control ahead to the 1/2 throttle position, and disengage the parking brake.

   1. Move the bypass levers into the pushing the machine position. With the bypass valves open and the engine running, slowly move the motion-control levers in both forward and reverse 5 or 6 times.

   2. Move the bypass levers into the operating the machine position.

   3. With the bypass valve closed and the engine running, slowly move the control lever in both forward and reverse directions 5 to 6 times.

   4. Shut off the engine and check the fluid level in the expansion reservoir. Add the specified fluid until it reaches the FULL COLD line on the expansion reservoir.

3. Repeat step 2 until all the air is completely purged from the system.

   Note: When the transaxle operates at normal noise levels, moves smoothly forward, and reverses at normal speeds, it is purged.

4. Check the fluid level in the expansion reservoir a final time. Add the specified fluid as until it reaches the FULL COLD line on the expansion reservoir.

Check to ensure that the mower deck is level any time you install the mower or when you see an uneven cut on your lawn.

Check the mower deck for bent blades prior to leveling, and remove and replace any bent blades; refer to Checking for Bent Blades before continuing.

Level the mower deck side-to-side first; then you can adjust the front-to-rear slope.

Requirements:

• The machine must be on a level surface.

• All tires must be properly inflated; refer to Checking the Tire Pressure.

1. Park the machine on a level surface, 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. Position the mower deck in the transport-lock position.

5. Carefully rotate the blades from side to side.

6. Measure between the blade tip and the flat surface (Figure 94). If both measurements are not within 5 mm (3/16 inch), adjust the leveling; continue with this procedure.

   

   Figure 94

   1. Blades side to side
   2. Blade tip
   3. Measure from the tip of the blade to the flat surface here.

7. Check the front-to-rear blade level (Figure 95). Ensure the front blade tip is lower than the rear blade tip as shown in the block height and rake table. If adjustment is needed, continue with this procedure.

   

   Figure 95

   1. Blades front to rear
   2. Blade tip
   3. Measure from the tip of the blade to the flat surface here.

8. Set the anti-scalp rollers to top holes or remove them completely for this adjustment.

9. For 60-inch mower decks only:

   1. Raise the deck to the transport position (12.7 cm or 5 inches).

   2. Slowly loosen the adjusting screw on the lift-assist spring until you can remove the screw (see Figure 96).

      Note: Save the screw for installation.

   

   Figure 96

   Rear discharge mower deck shown

   1. Adjusting screw
   2. Bracket
   3. Set the gap to 22 to 29 mm (7/8 to 1-1/8 inch).

10. Place 2 blocks (see Block Height and Rake Table) under the rear edge of the cutting deck skirt; 1 on each side of the cutting deck (Figure 97).

11. Set the height-of-cut lever to the 3 inch (76 mm) position.

12. Place 2 blocks under each side of the front edge of the deck, but not under the anti-scalp roller brackets or welds.

    

    Figure 97

    Bottom view

    1. Block—7.3 cm (2.87 inches)
    2. Welds

    Block Height and Rake Table

    Deck Size	Front Block Height	Rake
    All mower decks	7.3 cm (2.87 inches)	4.8 to 6.4 mm (3/16 to 1/4 inch)

13. Carefully rotate the blades side to side (Figure 94).

14. Loosen the locknuts (Figure 98) on all 4 corners and ensure that the mower deck is sitting securely on all 4 blocks.

15. Remove any slack from the deck hangers and make sure the deck-lift foot lever is pushed back against the stop.

16. Tighten the 4 locknuts.

    

    Figure 98

    1. Locknuts
    2. Deck lift arm
    3. Deck hanger
    4. Chain

17. Ensure that the blocks fit snugly under the deck skirt and that all attachment bolts are tight

18. Continue leveling the deck by checking the front-to-rear blade slope.

19. Check the blades for levelness and repeat deck leveling procedure if necessary.

20. For 60-inch mower decks only:

    1. Raise the deck to the transport position (12.7 cm or 5 inches).

    2. Install the lift-assist spring adjusting screw previously removed in step 9.

    3. Set the gap between the spring and the bracket to 22 to 29 mm (7/8 to 1-1/8 inch).

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

1. Park the machine on a level surface, 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. Place the height-adjustment pin in the 7.6 cm (3 inch) cutting-height location.

4. Remove the belt covers.

5. Loosen the mower deck idler and remove the mower belt; refer to Belt Maintenance.

6. Remove the bolts and nuts from the front of the plate under the footrest.

7. Remove and retain the bolts and nuts on both sides of the machine (Figure 99).

   

   Figure 99

   1. Remove the nuts and bolts here.
   2. Remove the nuts and bolts here.

8. 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 100).

2. Remove the damaged or worn grass deflector (Figure 100).

   

   Figure 100

   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 100.

5. Install the bolt and the nut.

6. Place 1 J-hook end of the spring around the grass deflector (Figure 100).

   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. Park the machine on a level surface, 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 the mower deck to the TRANSPORT position.

Use compressed air to clean the suspension system.

Note: Do not clean the shock assemblies with pressurized water (Figure 101).

Figure 101

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