ProLine H800 Rotary Mower

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

Front and rear tires air pressure specification: 140 kPa (20 psi).

Caster tires air pressure specification: 150 kPa (21 psi).

Check the air pressure in the front and rear tires. Add or remove air as needed to set the air pressure in the tires to the tire air pressure specification.

Important: Maintain pressure in all tires to ensure a good quality of cut and proper machine performance.Check the air pressure in all the tires before operating the machine.

Figure 13

The purpose of the safety-interlock system is to prevent the engine from cranking or starting unless the traction pedal is in neutral, the PTO switch is in the OFF position, the parking brake is engaged, or the operator is in the seat.

In addition, the engine should shut off when:

• The operator leaves the seat with the PTO switch in the ON position;

• The operator leaves the seat with the traction pedal out of neutral;

• The traction pedal is pressed with the parking brake engaged.

Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.

Fuel tank capacity: 41 L (10.8 US gallons)

Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter-grade (No. 1-D or No. 1-D/2-D blend) below that temperature. Using winter-grade fuel at lower temperatures provides lower flash point and cold flow characteristics which will ease starting and reduce fuel filter plugging.

Using summer-grade fuel above -7°C (20°F) will contribute toward longer fuel pump life and increased power compared to winter-grade fuel.

Important: Do not use kerosene or gasoline instead of diesel fuel. Failure to observe this caution will damage the engine.

Filling the Fuel Tank

Note: If possible, fill the fuel tank after each use; this minimizes possible buildup of condensation inside the fuel tank.

Figure 14

Adjust the tilt-steering column to your desired position as shown in Figure 17.

Figure 17

The seat moves forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

To adjust, pull the lever upward and move the seat forward or rearward (Figure 18).

Figure 18

1. Pull the seat-suspension lever out (Figure 19).

2. While sitting in the seat, adjust the seat suspension as follows:

   • For firmer suspension, pull the seat-suspension lever up as many times as necessary.

   • For softer suspension, push the seat-suspension lever down as many times as necessary.

3. When the arrow is in the middle, push the lever back in.

Figure 19

Pull the lever (Figure 20) upward to tilt the back of the seat.

Figure 20

Rotate the seat lumbar support (Figure 21) counterclockwise to increase the lumbar support.

Rotate the seat lumbar support clockwise to decrease the lumbar support.

Figure 21

Lift the seat-tilt lever (Figure 22) upward and tilt the seat forward.

Figure 22

Important: You may need to bleed the fuel system when starting a new machine, the engine no longer runs due to lack of fuel, or you have replaced or serviced the fuel system components.

1. Raise the roll bar and lock it into place.

2. Sit on the seat and fasten the seat belt.

3. Ensure that the parking brake is set and the PTO switch is in the OFF position.

4. Remove your foot from traction pedal and ensure that it is in neutral.

5. Rotate the key switch to the ON/PREHEAT position.

   Note: An automatic timer then controls the preheat for a few seconds.

6. After preheating, rotate the key switch to the Start position, crank the engine for no longer than 15 seconds, and release the key when the engine starts.

   Note: If additional preheating is required, turn the key to the OFF position, then to the ON/PREHEAT position. Repeat this process as required.

7. Move the throttle to idle speed or partial throttle and run the engine until it warms up.

   Important: When you start the engine for the first time; or after you change the engine oil, hydraulic fluid, overhaul the engine, or replace traction components; operate the machine in forward and reverse for 1 to 2 minutes. Also, operate the lift lever and PTO lever to ensure that all parts are properly operating. Turn the power-steering wheel to the left and right to check the steering response. Then shut the engine off, check the fluid levels, and check for oil leaks, loose parts, and any other malfunctions.

1. Move the throttle control rearward to the SLOW position.

2. Move the PTO switch to the OFF position.

3. Rotate key switch to the OFF position. Remove key from the switch to prevent accidental starting.

Note: If the engine stops running and the key switch is in the LIGHTS ON or the ON/PREHEAT position, and you leave the operator's seat, after a short delay a buzzer will sound to alert you to turn the key to the OFF position.

1. Push the brake pedal down.

2. Push the parking-brake lock down and remove your foot from the brake pedal to engage the parking brake.

Push the brake pedal down to disengage the parking brake.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Raise the hopper and secure it; refer to Raising the Hopper and Securing the Hopper in the Raised Position.

4. Shut off the engine and remove the key.

5. Tilt the seat forward.

6. Unlatch the grass chute (Figure 27).

   

   Figure 27

   1. Handle
   2. Latch
   3. Chute

7. Using the handle on the chute, remove the chute and clear it and the mower deck opening (Figure 27).

8. Install the chute and secure it with the latches (Figure 27).

If the hopper sensor activates and the PTO automatically disengages when the hopper is not full or if the chute clogs before the sensor activates, you need to adjust the sensor position.

Adjust the sensor as follows:

1. Open the hopper door.

2. Adjust the hopper sensor based on the following:

   • For normal grass and weather conditions, rotate the sensor to the mid-point position (Figure 28).

   • For wet, dense grass conditions, when picking up leaves, or if the hopper fills before the sensor activates, rotate the sensor downward (Figure 28).

   • For dry, sparse grass conditions, or if the mower deck disengages before the hopper fills, rotate the sensor upward (Figure 28).

   

   Figure 28

   1. Position the hopper sensor upward when grass is thin or conditions are dry.
   2. Position the hopper sensor in the middle when grass and weather conditions are normal.
   3. Position the hopper sensor downward when grass is thick, contains leaves, or conditions are wet.

You can adjust the height of cut continually from 20 to 110 mm (3/4 to 4-1/4 inches) by using the height-of-cut switch.

Push the height-of-cut switch (Figure 8) forward to lower the height of cut. Push the height-of-cut switch rearward to increase the height of cut.

Read the height of cut indicator on the height-of-cut gauge to ensure that it is set at the desired height.

Monitor the height-of-cut gauge as you mow and adjust the height of cut if needed.

Mount the skids in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches).

Adjust the skids as shown in Figure 29.

Figure 29

Mount the roller in the lower position when operating at heights of cut greater than 51 mm (2 inches) and in a higher position when operating at heights of cut lower than 51 mm (2 inches).

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the roller shaft, bolt, and nut securing the roller to the deck bracket (Figure 30).

   

   Figure 30

   1. Nut
   2. Roller shaft
   3. Bolt
   4. Roller

5. Align the roller with the appropriate holes and install the shaft with the bolt and nut (Figure 31).

   

   Figure 31

   1. Nut
   2. Roller shaft
   3. Bolt
   4. Roller

Mount the rollers so that there is a 19 mm (3/4 inch) clearance from the ground.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the lock pin from the roller pin (Figure 32).

   

   Figure 32

   1. Roller pin
   2. Lock pin

5. Move the roller pin up or down to the desired position and secure it with the lock pin (Figure 32).

6. Repeat steps 4 and 5 on the other side and ensure that it matches the other setting.

Note: If you leave the operator’s seat while the PTO switch is in the ON position, the machine will automatically shut off the engine.

Perform the following to reset the PTO function:

1. Push in the PTO switch knob.

2. Rotate the key to the OFF position.

3. Rotate the key to the ON/PREHEAT position, then start the engine.

4. Pull out the PTO switch knob.

• Practice driving before operating the machine, because it has a hydrostatic transmission and its characteristics are different than some turf-maintenance machines.

• To maintain enough power for the machine and deck while mowing, regulate the traction pedal to keep the engine speed (rpm) high and constant. Decrease the ground speed as the load on the cutting blades increases; increase the ground speed as the load on the blades decreases. This allows the engine, working with the transmission, to sense the proper ground speed while maintaining a high blade-tip speed necessary for good quality of cut. Therefore, allow the traction pedal to move upward as the engine speed decreases, and press pedal slowly as the speed increases. When driving from 1 work area to another (with no load and the deck raised), have throttle in the FAST position and press the traction pedal slowly but fully to attain the maximum ground speed.

• Before shutting off the engine, move all controls to the NEUTRAL position and move the throttle to the SLOW position. Rotate the key switch to the OFF position to shut off the engine.

• The engine does not run when the engine coolant is in over-temperature condition. Let the engine and cooling system cool, and check the cooling system; refer to Checking the Cooling System and Coolant Level.

• It is important to carry socket wrench with a 100 mm extension and 17 mm socket while operating the machine. Use the socket wrench to open the bypass valve if you need to push or tow the machine.

Operator provided tool: a socket wrench with a 17 mm socket and 100 mm extension.

In case of an emergency, you can tow the machine a very short distance. However, Toro does not recommend this as standard procedure.

Important: Pushing or towing the machine faster than 3 to 5 km/h (2 to 3 mph) may damage the transmission. If you must move the machine a long distance, transport it on a truck or trailer. Whenever you push or tow the machine, open the bypass valve.

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

• Use full-width ramps for loading the machine into a trailer or a truck.

• Before tying down machine, lower the deck completely.

• Bind the machine securely to the transport vehicle using straps, chains, cable, or ropes. Align both front and rear straps down and outward from the machine.

Binding the Front of the Machine

Loop tie-downs around the corners of the carrier frame or use the anchor hoops where provided. (Figure 34 and Figure 35).

Figure 34

Machines with 1 anchor hoop on the carrier frame

1. Front tie-down locations

Figure 35

Machines with 2 anchor hoops on the carrier frame

1. Front tie-down loop locations

Binding the Back of the Machine

Machines without Rear Anchor Hoops

Insert a bolt or drawbar pin into the hitch and use it as the rear tie-down point (Figure 36).

Figure 36

Binding the Back of the Machine

Machines with Rear Anchor Hoops

Secure the back of the machine at the 2 anchor hoops at the rear bumper (Figure 37).

Figure 37

1. Rear anchor hoop locations

1. Rotate the radiator or fuel tank out; refer to Accessing the Engine from the Right side or Accessing the Engine from the Left Side.

2. Place a jack under the frame tube (Figure 38 and Figure 39), directly under the ROPS tube, or as close as possible.

   

   Figure 38

   1. Frame tube on the right side of the machine
   

   Figure 39

   1. Frame tube on the left side of the machine

Jack up the rear, left or rear, right side of the machine using the jacking points shown in Figure 40.

Figure 40

1. Rear jacking points

1. Park the machine on a level surface.

2. Raise the hopper to the fully raised position; refer to Raising the Hopper.

3. Secure the hopper by performing the following:

   1. Push the pin on magnetic safety lock inward (Figure 41).

   2. While still holding the pin in, lower magnetic safety lock onto the hydraulic cylinder (Figure 41).

   3. Repeat steps 1 and 2 on the other side.

   

   Figure 41

Grease specification: No. 2 lithium grease

Important: Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

Note: Lubricate the grease fittings immediately after every washing, regardless of interval specified.

1. Remove the belt cover; refer to Removing the Belt Cover.

2. Wipe grease fitting clean so debris is not forced into the bearing or bushing.

3. Pump grease into the bearing or bushing.

4. Wipe off excess grease.

5. Install the belt cover; refer to Installing the Belt Cover.

Figure 42

Grease specification: No. 2 lithium grease

Important: Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

Note: Lubricate the grease fittings immediately after every washing, regardless of interval specified.

1. Wipe grease fitting clean so debris is not forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

The bearing and bushing lubrication points are as follows:

• Brake and traction pedal pivot bushings (Figure 43)

  

  Figure 43

• Rod fittings for the deck-lift cylinders (Figure 44).

  

  Figure 44

• Deck lift arm pivot points (Figure 45)

  

  Figure 45

• PTO idler-pulley bracket (Figure 46)

  

  Figure 46

• Hopper arms—upper (Figure 47)

  

  Figure 47

• Hopper arms—lower, front (Figure 48)

  

  Figure 48

  Left side shown; repeat on other side

• Hopper arms—lower, rear (Figure 49)

  

  Figure 49

• Hopper pivots under the hopper (Figure 50)

  

  Figure 50

• Steering pivot points (Figure 51)

  

  Figure 51

Grease specification: No. 2 lithium grease

Important: Dusty and dirty operating conditions could cause dirt to get into the bearings and bushings, resulting in accelerated wear.

Note: Lubricate the grease fittings immediately after every washing, regardless of interval specified.

1. Wipe grease fitting clean so debris is not forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

• Forward U-joint of the driveshaft at the mower gearbox (Figure 52).

  

  Figure 52

• Rear U-joint of the driveshaft at the PTO (Figure 53).

  

  Figure 53

Lubrication specification: anti-sieze compound

1. Disconnect the driveshaft from the mower-deck gearbox; refer to Disconnecting the Driveshaft from the Mower-Deck Gearbox.

2. Pull the front half of the driveshaft (Figure 54) forward about 25 cm (10 inches).

   

   Figure 54

   1. 25 cm (10 inches)
   2. Splines (U-joint coupling)
   3. Splines (gearbox shaft)
   4. Splines (driveshaft)

3. Wipe clean the splines of the gearbox shaft and the splines of the driveshaft (Figure 54).

4. Wipe clean the sliding surface of the forward driveshaft (Figure 54).

5. Apply anti-sieze compound to the splines of the gearbox shaft and U-joint coupling (Figure 54).

6. Apply anti-sieze to the sliding surface of the forward driveshaft (Figure 54).

7. Move the front half of the driveshaft rearward to align the U-joint coupling with the gearbox shaft.

8. Wipe off excess anti-sieze compound from the driveshaft.

9. Connecting the driveshaft to the mower-deck gearbox; refer to Connecting the Driveshaft to the Mower-Deck Gearbox.

Note: Replace the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Cleaning the Air-Cleaner Cover

Maintenance Service Interval	Maintenance Procedure
Every 50 hours	Remove the air-cleaner cover and clean out the debris. Do not remove the filter.

Note: Do not use compressed air to clean the cover or air filter(s).

Check the air-cleaner body for damage which could cause an air leak. Replace a damaged air-cleaner body.

Clean the air-cleaner cover as shown in Figure 60.

Figure 60

The engine ships with oil in the crankcase.

Crankcase capacity: approximately 3.4 L (3.6 US qt) with the filter.

Engine oil specification:

• Engine oil-type—API Classification Level Required: CH-4, CI-4 or higher.

• Engine oil viscosity

  • Preferred oil: SAE 15W-40 (above 0°F)

  • Alternate oil: SAE 10W-30 or 5W-30 (all temperatures)

Note: Toro Premium Engine Oil is available from your authorized Toro distributor in either 15W-40 or 10W-30 viscosity. See the parts catalog for part numbers.

Checking the Engine-Oil Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Check the engine-oil level.Check the engine-oil level before the engine is first started and daily thereafter.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If you have already run the engine, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the low mark on the dipstick, add oil to bring the oil level to the high mark. Do not overfill. If the oil level is between the high and low marks, you do not need to add oil.

Check the engine-oil level as shown in Figure 62.

Figure 62

At the left side of the engine, operate the lever of the fuel pump until you fill the fuel-filter bowl (Figure 64).

Figure 64

1. Lever
2. Fuel pump

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Ensure that the fuel tank is at least half full.

4. Unlatch the radiator; refer to Accessing the Engine from the Right side.

5. Place a drain pan under the air-bleed screw.

6. Open the air-bleed screw on the fuel-injection pump (Figure 65).

   

   Figure 65

   1. Air-bleed screw

7. Operate the lever of the fuel pump until you see solid stream of fuel flows out around the screw; refer to Figure 64 in Priming the Fuel System.

8. Tighten the air-bleed screw (Figure 65).

   Note: The engine should start after you perform this procedure. However, if the engine does not start, air may be trapped between the injection pump and the injectors. Contact your authorized Toro distributor.

9. Wipe clean any fuel that has accumulated around the injection pump.

1. Clean the area around the fuel-filter head (Figure 72).

   

   Figure 72

   1. Fuel-filter head
   2. Filter

2. Remove the filter and clean the filter-head-mounting surface (Figure 72).

3. Lubricate the filter gasket with clean fuel.

4. Assemble the filter element onto the filter head.

5. Assemble the filter bowl and bowl nut onto the filter head and tighten the nut by hand

6. Prime the fuel system; refer to Priming the Fuel System.

7. Check the fuel/water separator for leaks.

   Note: Repair all fuel leaks before operating the machine.

Figure 73

• If you store the machine for an extended period, use a siphon pump to empty the fuel tank (Figure 73).

• If the fuel system becomes contaminated, use a siphon pump to empty the fuel tank (Figure 73), clean the tank, and use clean diesel fuel to flush out the tank.

Inspect the fuel lines for deterioration, damage, or loose connections.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the 3 socket-head screws from the left console (Figure 74).

5. Remove the throttle-lever knob (Figure 74).

6. Lift the left console up and set it aside (Figure 74).

Figure 74

1. Slotted hex screw
2. Throttle-lever knob
3. Left console

Important: Before welding on the machine, disconnect the negative cable from the battery to prevent damage to the electrical system.

Installing the Battery

Install the battery as shown in Figure 76.

Figure 76

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.

The fuse block and fuses are located to the left of the operator’s seat (Figure 78).

Figure 78

1. Fuse block

Use the following table when replacing a fuse:

Safety Fuses—Figure 79

Figure 79

1. Security fuse (3 A)
2. PTO fuse (15 A)
3. Electronic control unit and buzzer fuse (5 A)
4. Differential lock fuse (5 A)
5. Mower deck valve and operator’s seat fuse (15 A)
6. Alternator and dashboard fuse (5 A)
7. Work lights, brake lights, full-beam lights, and light control unit fuse (15 A)
8. Pull and hazard light switch, spark plugs, and key switch fuse (30 A)

Light Fuses—Figure 80

Figure 80

1. Right steady light and plate light fuse (3 A)
2. Left steady light fuse (3 A)
3. Full-beam light fuse (15 A)
4. Headlight fuse (10 A)
5. Warning device fuse (10 A)
6. Indicator lights fuse (7.5 A)
7. Rotating beacon light fuse (5 A)
8. Hazard-light switch fuse (15 A)

There are also 2 fuses (40 A) that protect the main machine wire harness (Figure 81).

Figure 81

1. Fuses (40 A)

Prevent corrosion of wiring terminals by applying Grafo 112X (Skin-over) grease, Toro Part No. 505-47, to the inside of all harness connectors whenever you replace the harness.

Important: Whenever working with the electrical system, always disconnect the battery cables, negative (-) cable first, to prevent wiring damage from short-outs.

Wheel lug nut torque specification: 85 to 90 N∙m (62 to 66 ft-lb)

Torque the lug nuts at the front and rear wheels in a crossing pattern as shown in Figure 82 to the specified torque.

Figure 82

The rear-axle-steering stops help prevent over-travel of the steering cylinder in case of impact on the rear wheels. Adjust the stops so that there is 0.23 cm (0.090 inch) clearance between the bolt head and the knuckle on the axle when you turn the steering wheel completely to the left or to the right.

Thread the bolts in or out until you attain a clearance of 0.23 cm (0.090 inch); refer to Figure 84.

Figure 84

1. Steering stop (right side shown)

Cooling system capacity: 7.5 L (8 US qt)

Coolant-type specification:

1. Check the level of the coolant in the expansion tank (Figure 85).

   

   Figure 85

   1. Expansion tank
   2. Cold line—19 mm (3/4 inch) from the bottom
   3. Hot line—19 mm (3/4 inch) from the top

2. If the coolant is low, remove the expansion-tank cap and add the recommended replacement coolant as required.

   Do not use water only or alcohol-based coolants.Do not overfill.

3. Install the expansion-tank cap.

To prevent the engine from overheating, keep the radiator screen and radiator clean. Check the radiator screen and radiator for buildup of grass, dust, and debris, and if necessary, clean any debris off these parts.

Note: If the PTO shuts off due to high engine temperature, first check the radiator screen and radiator for an excessive buildup of debris. Clean the system before operating the machine. Do not shut off the engine immediately; allow the engine to cool by running it without a load.

Clean the radiator as follows:

1. Remove the radiator screen.

2. Working from the fan side of the radiator, blow with low pressure, 172 kPa (25 psi), compressed air (do not use water). Repeat this step from the front of the radiator and again from the fan side.

3. After you have thoroughly cleaned the radiator, clean out any debris that may have collected in the channel at the radiator base.

4. Clean the radiator screen and install it onto the machine.

After adjusting the service brakes after the first 50 hours of operation, you may need to adjust the brakes again after considerable use.

You should measure a gap approximately a 13 mm (1/2 inch) between the brake pedal to the front end of the slot when the brake pedal is pressed down fully.

1. Push the brake pedal down to check if there is a sufficient gap in the front end of the slot (Figure 86).

   

   Figure 86

   1. Brake pedal
   2. Gap

2. Release the brake pedal.

3. If an adjustment is necessary, loosen the front and rear jam nuts on each side of the brake cables (Figure 87).

   

   Figure 87

   1. Brake cable
   2. Jam nut

4. Push the brake pedal down and move the brake cables forward or rearward.

5. Tighten the jam nuts to lock the cable positions.

6. Repeat steps 3 through 5 until you set the brake pedal to the desired position.

Check alternator belt for wear or damage.

Note: Replace the alternator belt if you find it worn or damaged.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Access the engine from the left side; refer to Accessing the Engine from the Left Side.

5. Loosen the alternator pivot bolt and lock bolt (Figure 88).

6. Tension the alternator belt until you achieve 10 mm (3/8 inch) belt deflection midway between the pulleys with a force of 4.5 kg (10 lb).

7. Tighten the alternator lock bolt (Figure 88).

8. Tighten the alternator pivot bolt (Figure 88).

Figure 88

1. Alternator lock bolt
2. Alternator
3. Alternator pivot bolt
4. Alternator belt

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Raise and secure the hopper; refer to Raising the Hopper and Securing the Hopper in the Raised Position.

4. Shut off the engine and remove the key.

5. Open the engine-access cover; refer to Accessing the Engine from the Engine-Access Cover.

6. Adjust the air gap so that a 0.4 mm (0.015 inch) feeler gauge slides in between the clutch lining and friction plate with light pressure (Figure 95).

   Note: You can decrease the gap by turning the adjusting nut clockwise (Figure 95). The maximum service gap is 0.7 mm (0.030 inch). Adjust all 3 air gaps.

   

   Figure 95

   1. Clutch
   2. 0.4 mm (0.015 inch) air gap (3)
   3. Adjusting nut (3)
   4. Electrical connector
   5. PTO belt

7. After you have set all 3 gaps, check the 3 gaps again.

   Note: Adjusting 1 gap can alter the other gaps.

The hydraulic-fluid reservoir is filled at the factory with high-quality hydraulic fluid. Check the level of the hydraulic fluid before you start the engine for the first time and daily thereafter.

Use Toro Premium All-Season Hydraulic Fluid (Available in 5-gallon pails or 55-gallon drums. See the Parts Catalog or Toro distributor for part numbers.)

If the Toro fluid is not available, you may use other fluids provided that they meet all the following material properties and industry specifications. Consult with your lubricant distributor to identify a satisfactory product.

Note: Toro does not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

High-Viscosity Index/Low-Pour Point Anti-Wear Hydraulic Fluid, ISO VG 46

Important: The ISO VG 46 multigrade fluid offers optimal performance in a wide range of temperature conditions. For operation in consistently high ambient temperatures, 65°F (18°C) to 120°F (49°C), ISO VG 68 hydraulic fluid may offer improved performance.

Important: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic-system oil is available in 20ml (2/3 fl oz) bottles. 1 bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic oil. Order Toro Part No. 44-2500 from your authorized Toro distributor.

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Raise the hopper and engage the magnetic safety locks; refer to Securing the Hopper in the Raised Position.

4. Unlatch and remove the grass chute; refer to Clearing the Grass Chute.

5. Pull and rotate the rear link pins on both sides of the mower deck.

6. Raise the mower deck.

7. Shut off the engine and remove the key.

8. Using the handle and foot peg on the left side of the mower deck, rotate the front of the mower deck upward to the maintenance position.

Important: Ensure that you remove the grass chute before performing this procedure; otherwise, damage may occur.

1. Park the machine on a level surface.

2. Lower the mower deck.

3. Rotate the rear link pins to release them into the rear links.

4. Insert the grass chute, rotate the operator’s seat, and lower the hopper.

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.

Replace the blades if they hit a solid object, they are out of balance, or a they are bent. To ensure best performance and continued safety conformance of the machine, use genuine Toro replacement blades. Replacement blades made by other manufacturers may not meet the safety standards.

1. Rotate the quarter-turn fastener and open the universal-joint cover from the belt cover (Figure 112).

   

   Figure 112

   1. U-joint cover
   2. Quarter-turn fastener
   3. Mower-deck gearbox
   4. Universal joint (driveshaft)
   5. Spring-loaded pin

2. Disconnect the forward end of the driveshaft from the mower-deck gearbox by pressing the spring-loaded pin, and then pulling the end of the driveshaft rearward (Figure 112).

1. Align the splines of the driveshaft-universal joint with the splines in the gearbox coupling; refer to Figure 112 in Disconnecting the Driveshaft from the Mower-Deck Gearbox.

2. Press the spring-loaded pin and then push the end of the driveshaft forward; refer to Figure 112 in Disconnecting the Driveshaft from the Mower-Deck Gearbox.

3. Release the spring-loaded pin and check that the universal joint of the driveshaft is locked into the mower-deck gearbox; refer to Figure 112 in Disconnecting the Driveshaft from the Mower-Deck Gearbox.

4. Close the universal-joint cover and secure it to the belt cover with the quarter-turn fastener; refer to Figure 112 in Disconnecting the Driveshaft from the Mower-Deck Gearbox.

1. Park the machine on a level surface.

2. Disengage the PTO and engage the parking brake.

3. Before lowering the deck, pull and rotate the rear link pins at both sides of the mower deck (Figure 113).

   

   Figure 113

   1. Rear link pins

4. Disconnect the hydraulic hoses from each side of the traction unit (Figure 114).

   

   Figure 114

   1. Outboard hose (red colored identifier)
   2. Inboard hose (blue colored identifier)
   3. Right side of the machine
   4. Left side of the machine

5. Lower the mower deck and tilt the hopper back.

6. Shut off the engine and remove the key.

7. Tilt the seat forward.

8. Remove the grass chute; refer to Clearing the Grass Chute.

9. Disconnect the universal joint of the driveshaft from the mower-deck gearbox; refer to Disconnecting the Driveshaft from the Mower-Deck Gearbox.

10. Remove the 2 lynch pins and 2 clevis pins that secure the lift arms at each side of the mower deck (Figure 115).

    

    Figure 115

    1. Lynch pins
    2. Lift arms
    3. Clevis pins

11. Roll the mower deck forward and away from the traction unit.

1. Park the machine on a level surface.

2. Tilt the hopper back.

3. Shut off the engine and remove the key.

4. Remove the grass chute; refer to Clearing the Grass Chute.

5. Roll the mower deck rearward to the traction unit.

6. Install the lynch pin and clevis pin to secure the lift arms on each side; refer to Figure 115 in Removing the Mower Deck.

7. Connect the universal joint of the driveshaft from the mower-deck gearbox; refer to Connecting the Driveshaft to the Mower-Deck Gearbox.

8. Install the grass chute; refer to Clearing the Grass Chute.

9. Tilt the seat rearward.

10. Start the engine.

11. Lower the hopper.

12. Raise the mower deck until the castor wheels are slightly off the ground.

13. Rotate the rear link pins to engage the mower deck rear lift links; refer to Figure 113 in Removing the Mower Deck.

14. Connect the hydraulic hoses as follows:

    1. Connect the hydraulic hose marked with a blue identifier to the inboard quick-disconnect coupler (marked with a blue identifier); refer to Figure 114 in Removing the Mower Deck.

    2. Connect the hydraulic hose marked with a red identifier to the outboard quick-disconnect coupler (marked with a red identifier); refer to Figure 114 in Removing the Mower Deck.

    3. Repeat steps 1 and 2 for the hydraulic hoses at the other side of the mower deck.

Note: You must separate the U-joint of the driveshaft from the mower-deck gearbox before removing the belt cover; refer to Disconnecting the Driveshaft from the Mower-Deck Gearbox.

1. Rotate the 3 quarter-turn fasteners counterclockwise (Figure 116).

   

   Figure 116

   1. Quarter-turn fasteners
   2. Bolt

2. Loosen the bolt (Figure 116).

3. Remove the belt cover from the mower deck.

1. Align the quarter-turn fasteners of the belt cover with the clip nuts of the mower deck; refer to Figure 116 in Removing the Belt Cover.

2. Rotate the quarter-turn fasteners clockwise.

3. Install the bolt in the belt cover to the nut clip of the mower deck; refer to Figure 116 in Removing the Belt Cover.

1. Remove the belt cover; refer to Removing the Belt Cover.

2. Remove the bolt and washer that secure the pulley cover to the mower deck (Figure 117).

   

   Figure 117

   1. Bolt
   2. Washer
   3. Pulley cover

3. Remove the pulley cover from the machine.

1. Align the pulley cover over the right-most pulley; refer to Figure 117 in Removing the Pulley Cover.

2. Secure the pulley cover to the clip nut of the deck with the bolt and washer that you remove in step 2 in Removing the Pulley Cover.

Gearbox oil specification: PG2 and API GL4, GL5, or MT1

Gearbox oil viscosity: LSX 75W90

Gearbox oil capacity: 112 ml (3.8 oz)

1. Park the machine on a level surface.

2. Disengage the PTO, lower the mower deck, and engage the parking brake.

3. Shut off the engine and remove the key.

4. Loosen or tighten the jam nut until the tension indicator arrow aligns with the outer surface of the washer (Figure 132).

   

   Figure 132

   1. Tension indicator arrow
   2. Belt-tensioning spring
   3. Washer
   4. Jam nut

When the skids wear out, you can switch them to the other side of the mower deck to gain additional use.

1. Park the machine on a level surface.

2. Disengage the PTO and engage the parking brake.

3. Rotate the mower deck to the maintenance position; refer to Rotating the Mower Deck into the Maintenance Position.

4. Shut off the engine and remove the key.

5. Remove the skids from the sides of the mower deck (Figure 135).

   

   Figure 135

6. Switch the skids and install them using the previously removed screws (Figure 135).

   Important: Use only the top 2 sets of holes when you install the skids.

1. Loosen the 4 bolts that secure the hopper lift supports to the pivot fittings (Figure 136).

   

   Figure 136

   1. Bolts

2. Slide the hopper forward or rearward until the hopper inlet aligns with the chute seal (Figure 137).

   

   Figure 137

   1. Chute seal
   2. Hopper inlet

3. Tighten the 4 bolts (Figure 136).

1. 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. Insert an air nozzle in the gap between the belt cover and the top of the mower deck. Use compressed air to clear any accumulated grass from under the mower deck belt cover.

1. 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. Prepare the mower deck for maintenance; refer to Rotating the Mower Deck into the Maintenance Position.

4. Remove any packed grass or debris, and clean as necessary.

1. Open the hopper door.

2. Pull the release lever on the bottom of the hopper screen downward (Figure 138).

   

   Figure 138

   1. Release lever
   2. Hopper screen

3. Remove the hopper screen and clean it (Figure 139).

   

   Figure 139

4. Install the hopper screen.

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

2. Raise the hopper (Figure 140) to the full height position; refer to Raising the Hopper.

   

   Figure 140

3. Dump the hopper (Figure 140) and leave it in the full dumped position, with the rear door hanging freely; refer to Dumping the Hopper.

   Note: The hopper door automatically unlatches when dumping the hopper.

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

5. Secure the raised hopper with the safety locks; refer to Figure 41 in Securing the Hopper in the Raised Position.

6. Using compressed air, clear the grass and debris from the slots in the bottom of the internal metal plate of the hopper door. (Figure 141).

   

   Figure 141

7. Secure the safety locks to their stowed position; refer to Figure 41 in Securing the Hopper in the Raised Position.

8. Rotate the hopper to the level position.

9. Lower the hopper; refer to Lowering the Hopper.

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