Toro 04351 Greensmaster 3050, Greensmaster 3050 Operator's Manual
Greensmaster) 3050
Greensmaster Traction Unit
Model No. 04351—Serial No. 260000001 and Up
Form No. 3354–728 Rev C
Operator’s Manual
Original Instructions (EN,GB)
Warning
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Page
Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . . .
Sound Pressure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Power 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 7. . . . . . . . . . . . . . . . .
Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 10. . . . . . . . . . . . . . . . . . . . . .
Accessories 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activating and Charging the Battery 12. . . . . . . . . . .
Installing the Rear Wheel Assembly 13. . . . . . . . . . .
Mounting the Seat 13. . . . . . . . . . . . . . . . . . . . . . . . .
Securing the Steering Arm 13. . . . . . . . . . . . . . . . . . .
Mounting the Cover 14. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Battery 14. . . . . . . . . . . . . . . . . . . . . . .
Installing the Cutting Units 15. . . . . . . . . . . . . . . . . .
Rear Ballast 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W 2005 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Before Operating 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil 17. . . . . . . . . . . . . . . . . . . .
Filling the Gas Tank 17. . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 18. . . . . . . . . . . . . . .
Tire Pressure 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Torque of the Wheel Nuts 19. . . . . . . .
Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Break-in Period 22. . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine 22. . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Interlock System 23. . . . . . . . . . . . . . .
Preparing the Machine for Mowing 24. . . . . . . . . . . .
Training Period 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Mowing 24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Mowing Procedures 24. . . . . . . . . . . . . . . . . . . . . . . .
Transport Operation 25. . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Cleanup After Mowing 25. . . . . . . . .
Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 26. . . . . . . . .
Daily Maintenance Checklist 27. . . . . . . . . . . . . . . . .
Lubrication 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Engine Oil and Filter 29. . . . . . . . . . . .
Servicing the Air Cleaner 30. . . . . . . . . . . . . . . . . . . .
Adjusting the Throttle Control 30. . . . . . . . . . . . . . . .
Adjusting the Choke Control 31. . . . . . . . . . . . . . . . .
Adjusting the Carburetor and Speed Control 31. . . . .
Replacing the Spark Plugs 31. . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 32. . . . . . . . . . . . . . . . . . . .
Changing the Hydraulic Oil and Filter 32. . . . . . . . . .
Checking the Hydraulic Lines and Hoses 33. . . . . . .
Adjusting the Brakes 33. . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Rear Camshaft 33. . . . . . . . . . . . . . . . .
Adjusting the Lift and Mow Pedal Height 34. . . . . . .
Leveling the Lift and Mow Pedals 34. . . . . . . . . . . . .
Adjusting the Traction Pedal 35. . . . . . . . . . . . . . . . .
Adjusting Cutting Unit Lift and Drop 35. . . . . . . . . .
Adjusting the Lift Cylinders 35. . . . . . . . . . . . . . . . .
Replacing the Seat Switch 36. . . . . . . . . . . . . . . . . . .
Replacing the Traction Switch 36. . . . . . . . . . . . . . . .
Replacing the Mow/Lift Switch 36. . . . . . . . . . . . . . .
Adjusting the Traction Return Linkage 37. . . . . . . . .
Servicing the Steering Assembly 37. . . . . . . . . . . . . .
Battery Care 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporative Emission Control Warranty Statement 47. . . .
The Toro General Commercial Products Warranty 48. . .
Contact us at www.Toro.com
All Rights Reserved
2
Printed in the USA
Introduction
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a dealer, or
to register your product.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
1
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
Safety
This machine meets or exceeds CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI
B71.4-1999 specifications in effect at the time of
production when 40 lb. of ballast is added to the rear
wheel.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
symbol, which means
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Safe Operating Practices
The following instructions are from the CEN standard EN
836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.
Training
• Read the operator’s manual and other training material
carefully. Be familiar with the controls, safety signs,
and the proper use of the equipment.
• Never allow children or people unfamiliar with these
instructions to use or service the mower. Local
regulations may restrict the age of the operator.
• Never mow while people, especially children, or pets
are nearby.
• Keep in mind that the operator or user is responsible for
accidents or hazards occurring to other people or their
property.
• Do not carry passengers.
• All drivers and mechanics should seek and obtain
professional and practical instruction. The owner is
responsible for training the users. Such instruction
should emphasize:
– the need for care and concentration when working
with ride-on machines;
3
– control of a ride-on machine sliding on a slope will
not be regained by the application of the brake. The
main reasons for loss of control are:
• insufficient wheel grip;
• being driven too fast;
• inadequate braking;
• the type of machine is unsuitable for its task;
• lack of awareness of the effect of ground
conditions, especially slopes;
• incorrect hitching and load distribution.
• The owner/user can prevent and is responsible for
accidents or injuries occurring to himself or herself,
other people, or property.
Operation
• Do not operate the engine in a confined space where
dangerous carbon monoxide fumes can collect.
• Mow only in daylight or in good artificial light.
• Before attempting to start the engine, disengage all
blade attachment clutches, shift into neutral, and engage
the parking brake.
• Remember there is no such thing as a safe slope. Travel
on grass slopes requires particular care. To guard
against overturning:
– do not stop or start suddenly when going up or
downhill;
– machine speeds should be kept low on slopes and
during tight turns;
Preparation
• While mowing, always wear substantial footwear, long
trousers, hard hat, safety glasses, and ear protection.
Long hair, loose clothing, or jewelry may get tangled in
moving parts. Do not operate the equipment when
barefoot or wearing open sandals.
• Thoroughly inspect the area where the equipment is to
be used and remove all objects which may be thrown by
the machine.
• Warning—Fuel is highly flammable. Take the
following precautions:
– Store fuel in containers specifically designed for this
purpose.
– Refuel outdoors only and do not smoke while
refuelling.
– Add fuel before starting the engine. Never remove
the cap of the fuel tank or add fuel while the engine
is running or when the engine is hot.
– If fuel is spilled, do not attempt to start the engine
but move the machine away from the area of
spillage and avoid creating any source of ignition
until fuel vapors have dissipated.
– Replace all fuel tanks and container caps securely.
• Replace faulty silencers/mufflers.
• Evaluate the terrain to determine what accessories and
attachments are needed to properly and safely perform
the job. Only use accessories and attachments approved
by the manufacturer.
• Check that operator’s presence controls, safety switches
and shields are attached and functioning properly. Do
not operate unless they are functioning properly.
– stay alert for humps and hollows and other hidden
hazards;
– never mow across the face of the slope, unless the
mower is designed for this purpose.
• Stay alert for holes in the terrain and other hidden
hazards.
• Watch out for traffic when crossing or near roadways.
• Stop the blades rotating before crossing surfaces other
than grass.
• When using any attachments, never direct discharge of
material toward bystanders nor allow anyone near the
machine while in operation.
• Never operate the machine with damaged guards,
shields, or without safety protective devices in place. Be
sure all interlocks are attached, adjusted properly, and
functioning properly.
• Do not change the engine governor settings or
overspeed the engine. Operating the engine at excessive
speed may increase the hazard of personal injury.
• Before leaving the operator’s position:
– stop on level ground;
– disengage the power take-off and lower the
attachments;
– change into neutral and set the parking brake;
– stop the engine and remove the key.
• Disengage drive to attachments when transporting or
not in use.
• Stop the engine and disengage drive to attachment
– before refuelling;
– before removing the grass catcher/catchers;
4
– before making height adjustment unless adjustment
can be made from the operator’s position.
– before clearing blockages;
– before checking, cleaning or working on the mower;
– after striking a foreign object or if an abnormal
vibration occurs. Inspect the mower for damage and
make repairs before restarting and operating the
equipment.
• Reduce the throttle setting during engine run-out and, if
the engine is provided with a shut-off valve, turn the
fuel off at the conclusion of mowing.
• Keep hands and feet away from the cutting units.
• Look behind and down before backing up to be sure of
a clear path.
• Slow down and use caution when making turns and
crossing roads and sidewalks. Stop cylinders/reels if not
mowing.
• Do not operate the mower under the influence of
alcohol or drugs.
• Use care when loading or unloading the machine into a
trailer or truck.
• Use care when approaching blind corners, shrubs, trees,
or other objects that may obscure vision.
• Disengage drives, lower the cutting units, set parking
brake, stop engine and remove key and disconnect spark
plug wire. Wait for all movement to stop before
adjusting, cleaning or repairing.
• Clean grass and debris from cutting units, drives,
silencers/mufflers, and engine to help prevent fires.
Clean up oil or fuel spillage.
• Use jack stands to support components when required.
• Carefully release pressure from components with stored
energy.
• Disconnect battery and remove spark plug wire before
making any repairs. Disconnect the negative terminal
first and the positive last. Reconnect positive first and
negative last.
• Use care when checking the cylinders/reels. Wear
gloves and use caution when servicing them.
• Keep hands and feet away from moving parts. If
possible, do not make adjustments with the engine
running.
• Charge batteries in an open well ventilated area, away
from spark and flames. Unplug charger before
connecting or disconnecting from battery. Wear
protective clothing and use insulated tools.
Toro Riding Mower Safety
Maintenance and Storage
• Keep all nuts, bolts and screws tight to be sure the
equipment is in safe working condition.
• Never store the equipment with fuel in the tank inside a
building where fumes may reach an open flame or
spark.
• Allow the engine to cool before storing in any
enclosure.
• To reduce the fire hazard, keep the engine,
silencer/muffler, battery compartment and fuel storage
area free of grass, leaves, or excessive grease.
• Check the grass catcher frequently for wear or
deterioration.
• Keep all parts in good working condition and all
hardware and hydraulic fittings tightened. Replace all
worn or damaged parts and decals.
• If the fuel tank has to be drained, do this outdoors.
• Be careful during adjustment of the machine to prevent
entrapment of the fingers between moving blades and
fixed parts of the machine.
• On multi-cylinder/multi-reel machines, take care as
rotating one cylinder/reel can cause other
cylinders/reels to rotate.
The following list contains safety information specific to
Toro products or other safety information that you must
know that is not included in the CEN, ISO, or ANSI
standard.
This product is capable of amputating hands and feet and
throwing objects. Always follow all safety instructions to
avoid serious injury or death.
Use of this product for purposes other than its intended use
could prove dangerous to user and bystanders.
Warning
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• Know how to stop the engine quickly.
• Do not operate the machine while wearing tennis shoes
or sneakers.
• Wearing safety shoes and long pants is advisable and
required by some local ordinances and insurance
regulations.
• Handle fuel carefully. Wipe up any spills.
5
• Check the safety interlock switches daily for proper
operation. If a switch should fail, replace the switch
before operating the machine. After every two years,
replace all four interlock switches in the safety system,
whether they are working properly or not.
• Before starting the engine, sit on the seat.
• Before disconnecting or performing any work on the
hydraulic system, all pressure in the system must be
relieved by stopping the engine and lowering the cutting
units and attachments to the ground.
• Check all fuel lines for tightness and wear on a regular
basis. Tighten or repair them as needed.
• Using the machine demands attention. To prevent loss
of control:
– Do not drive close to sand traps, ditches, creeks, or
other hazards.
– Reduce speed when making sharp turns. Avoid
sudden stops and starts.
– When near or crossing roads, always yield the
right-of-way.
– Apply the service brakes when going downhill to
keep forward speed slow and to maintain control of
the machine.
• The grass baskets must be in place during operation of
the cylinders/reels or thatchers for maximum safety.
Shut the engine off before emptying the baskets.
• Raise the cutting units when driving from one work
area to another.
• Do not touch the engine, silencer/muffler, or exhaust
pipe while the engine is running or soon after it has
stopped because these areas could be hot enough to
cause burns.
• Stay clear of the rotating screen at the side of the engine
to prevent direct contact with your body or clothing.
• If the engine stalls or loses headway and cannot make it
to the top of a slope, do not turn the machine around.
Always back slowly, straight down the slope.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the cutting units, attachments, and
any moving parts, especially the screen at the side of the
engine. Keep everyone away.
• To ensure safety and accuracy, have an Authorized Toro
Distributor check the maximum engine speed with a
tachometer. Maximum governed engine speed should be
2900 RPM.
• If major repairs are ever needed or if assistance is
desired, contact an Authorized Toro Distributor.
• Use only Toro-approved attachments and replacement
parts. The warranty may be voided if used with
unapproved attachments.
Sound Pressure
This unit has a maximum sound pressure level at the
operator’s ear of 82 dBA, based on measurements of
identical machines per Directive 98/37/EC.
Sound Power
This unit has a guaranteed sound power level of 105 dBA,
based on measurements of identical machines per Directive
2000/14/EC.
• When a person or pet appears unexpectedly in or near
the mowing area, stop mowing. Careless operation,
combined with terrain angles, ricochets, or improperly
positioned guards can lead to thrown object injuries. Do
not resume mowing until the area is cleared.
Maintenance and Storage
• Make sure all hydraulic line connectors are tight and all
hydraulic hoses and lines are in good condition before
applying pressure to the system.
• Keep your body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not your hands, to search for
leaks. Hydraulic fluid escaping under pressure can have
sufficient force to penetrate the skin and cause serious
injury. Seek immediate medical attention if fluid is
injected into skin.
Vibration
This unit does not exceed a hand/arm vibration level of
2
2.5 m/s
Directive 98/37/EC.
This unit does not exceed a whole body vibration level of
0.5 m/s
Directive 98/37/EC.
6
, based on measurements of identical machines per
2
, based on measurements of identical machines per
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
106-9071
1. To lock the parking brake,
press the brake pedal and
the parking brake lock.
93-8064 (for CE)
1. Warning—read the
instructions before
servicing or performing
maintenance.
93-8062
2. To unlock the parking
brake, press the brake
pedal.
3. Parking brake lock
2. Cutting hazard of foot or
hand—stop the engine
and wait for moving parts
to stop.
62–5070
93-6686
1. Hydraulic oil 2. Read the Operator’s
Manual.
93-9898
1. Lock and unlock the reels
7
1. Read the Operator’s Manual.
2. Off
3. Choke
107-2554
4. On
5. Slow
6. Continuous variable setting
7. Fast
8. Failure/malfunction (Leak
detector alarm test)
9. Headlights
10. Engine—stop
11. Engine—start
104-2053
104-2052
93-6691
1. Read the Operator’s Manual.
93-8063 (for CE)
1. Warning—read the Operator’s Manual.
2. Tipping hazard—do not use the machine on a slope greater
than 15 degrees.
3. Thrown object hazard—stay a safe distance from the machine.
4. Cutting hazard of hand or foot—stay away from moving parts.
5. Warning—lock the parking brake, stop the engine, and remove
the ignition key before leaving the machine.
93-8065
1. Transmission
2. Forward motion
3. Neutral
4. Forward speeds
8
93-8075
1. Press the lift pedal to
raise and stop the reels.
2. Press the mow pedal to
lower and start the reels.
93-8069
1. Hot surface/burn hazard—stay a safe distance from the hot
surface.
Battery Symbols
Some or all of these symbols are on your battery.
1. Explosion hazard
2. No fire, open flames, or
smoking.
3. Caustic liquid/chemical
burn hazard
4. Wear eye protection
5. Read the Operator’s
Manual.
6. Keep bystanders a safe
distance from the battery.
7. Wear eye protection;
explosive gases can
cause blindness and
other injuries
8. Battery acid can cause
blindness or severe
burns.
9. Flush eyes immediately
with water and get
medical help fast.
10. Contains lead; do not
discard.
9
Specifications
Note: Specifications and design subject to change without
notice.
General Specifications
Width of Cut 59 in. (149.9 cm)
Wheel Tread 49-1/2 in.
(125.7 cm)
Wheel Base 46-7/8 in.
(119.1 cm)
Overall Length 90 in. (228.6 cm)
Overall Width 69-3/4 in.
(117.2 cm)
Overall Height 48-1/2 in.
(123.2 cm)
Net Weight (wet) 930 lb. (422 kg)
Weight with Reels 1173 lb. (532 kg)
1st Gear Speed 3.8 MPH approx.
(6.1 km/h)
2nd Gear Speed 8.1 MPH approx.
(13.0 km/h)
Reverse Speed 1.9 MPH approx.
(3.1 km/h)
Reel Speed 1975 RPM approx.
Clip Speed—11 Blade Cutting Unit 0.18 in. approx.
(4.6 mm)
Clip Speed—8 Blade Cutting Unit 0.25 in. approx.
(6.4 mm)
Accessories
8 Blade DPA Cutting Unit Model No. 04610
11 Blade DPA Cutting Unit Model No. 04611
Spiker Model No. 04494
Tri-Roller Model No. 04495
Thatching Reels Model No. 04493
Variable Traction Speed Kit Model No. 04422
Individual Reel Shut Off Kit Part No. 28-2150
Backlapping Kit Part No. 92-9656
Spark Arrester Part No. 83-2240
High Altitude Jet* Part No. 805537
* Order from your local Briggs & Stratton Dealer
10
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Description Qty. Use
Seat
Nut, 5/16 in.
Seat cover
Wheel assembly
Rear spindle spacer
Capscrew, 1/2 x 3/4 in.
Washer, 1/2 in.
Cover
Socket head screw, 1/4 x 3/4 in.
Locknut, 1/4 in.
Washer, 1/4 in.
Self tapping screw
Capscrew, 1/4 x 5/8 in.
Nut, 1/4 in.
Gauge bar
Machine screw, #10 x 7/8 in.
Jam nut, #10 in.
1
4
1
1
2
1
1
1
1
1
1
2
2
2
1
1
1
Mounting the seat slide and seat cover to the
seat base
Mounting the rear wheel
Securing the steering arm
Mounting the cover
Securing the battery cables to the battery
Setting the height of cut
Grass basket 3 Mounts to the pull frame
Ignition keys 2
Service decal 11
Parts Catalog
Noise certificate
Pre-delivery sheet
Certificate of compliance
Operator video 1 Watch before operating the machine.
Operator’s Manual (traction unit)
Engine manual
Note: Mounting fasteners for the Greensmaster 3050 cutting unit are included with the cutting units.
1
1
1
1
2
1
Affix the appropriate language decal over
English decal 106–9071.
Read before operating the machine.
11
Activating and Charging the
Battery
Use only electrolyte (1.265 Specific Gravity) to fill battery
initially.
1. Remove the wing nuts, washers, and battery clamp and
lift out the battery.
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
Important Do not add electrolyte while the battery is in
the machine. You could spill it, causing corrosion.
2. Clean the top of the battery and remove the vent caps
(Fig. 2).
1
Figure 2
1. Vent caps
3. Carefully fill each cell with electrolyte until the plates
are covered with about 1/4 inch (6 mm) of fluid.
5. Connect a 3 to 4 amp battery charger to the battery
posts. Charge the battery at a rate of 3 to 4 amps until
the specific gravity is 1.250 or higher and the
temperature is at least 60_F (16_C) with all sells gasing
freely.
6. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
Note: After the battery has been activated, add only
distilled water to replace normal loss, although
maintenance–free batteries should not require water under
normal operating conditions.
Warning
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
1
Figure 3
1. Electrolyte
4. Allow approximately 20 to 30 minutes for the
electrolyte to soak into the plates. Refill as necessary to
bring the electrolyte to within about 1/4 inch (6 mm) of
the bottom of the fill well (Fig. 3).
Warning
Battery terminals or metal tools could short
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the tractor.
12
Installing the Rear Wheel
Mounting the Seat
Assembly
1. Remove the bolt and locknut from the wheel mount
holes in the rear castor fork (Fig. 4).
2. Install the rear wheel in the castor fork. Insert the bolt
into one of the mounting holes, install a spacer, and
slide the bolt through the wheel (Fig. 4).
2
1
Figure 4
1. Bolt
2. Spacer
3. Install another spacer onto the bolt and route the bolt
through the remaining castor fork mounting hole.
3. Locknut
3
Note: Mount the seat slides in the front set of mounting
holes to gain an additional 3 in. (7.6 cm) in the forward
adjustment, or in the rear mounting holes for an additional
3 in. (7.6 cm) in the rearward adjustment.
1. Support the seat base in the up position with the seat
support rod.
2. Remove the locknuts securing the seat slides to the
plywood shipping base. Discard the locknuts.
3. Secure the seat, seat panel, and seat slides to the seat
support with the locknuts (5/16 in.) (Fig. 6) supplied in
the loose parts. Mount the seat panel on the right side,
positioned as shown in Figure 6.
2
3
1
4. Position the bend of the bolt head under the bottom
edge of the castor fork. Install and tighten the locknut to
secure the wheel to the castor fork (Fig. 5).
5. Wipe the grease fitting clean on the wheel assembly.
Pump grease into the wheel hub until grease is seen
exiting at both hub bearings, thus ensuring the wheel
hub cavity is full. Wipe up any excess grease.
Figure 5
Figure 6
1. Seat support rod
2. Seat slide
3. Seat panel
Securing the Steering Arm
1. Remove the capscrew (1/2 x 3/4 in.) and washer
(1/2 in.) mounted to the outside of the steering arm
frame bracket.
2. Pivot the steering arm upward, aligning the mounting
holes in the arm with the holes in the frame bracket.
3. Select the desired mounting hole for operator comfort
and secure the arm with 2 capscrews (1/2 x 3/4 in.) and
washers (1/2 in.) (one each in loose parts) (Fig. 7).
13
1
3
Installing the Battery
1. Mount the battery with the battery terminals toward the
hydraulic tank on the machine.
Warning
Battery terminals or metal tools could short
2
against metal tractor components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
Figure 7
1. Capscrew and washer
2. Steering arm
3. Frame bracket
Mounting the Cover
1. Align the cover mounting holes with the holes in the
frame tube and mounting bracket (Fig. 8).
1
3
Figure 8
Shown with steering arm removed
1. Cover
2. Mounting bracket
2. Loosely secure the rear of the cover to the top of the
mounting bracket with a socket head screw (1/4 x
3/4 in.), washer (1/4 in.), and a locknut (1/4 in.) (Fig. 8).
3. Loosely secure the front of the cover to the frame tube
with two self tapping screws (Fig. 8). Tighten all of the
cover mounting fasteners.
3. Frame tube
2
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the tractor.
• Do not allow metal tools to short between the
battery terminals and metal parts of the tractor.
2. Connect the positive battery cable (red) from the starter
solenoid to the positive post (+) of the battery (Fig. 9).
Secure it with a wrench and coat the terminal with
petroleum jelly. Make sure the cable will clear the seat,
in the rear-most position, which could cause wear or
damage to the cable.
2
1
Figure 9
1. Negative (–) 2. Positive (+)
3. Connect the black ground cable from the engine base to
the negative (–) post of the battery. Secure it with a
wrench and coat the terminal with petroleum jelly.
4. Install the battery clamp and washers and secure them
with the wing nuts.
5. Place the terminal cover over
negative (–) battery posts.
the positive (+) and
14
Installing the Cutting Units
For Cutting Unit Models 04610 and 04611
Note: When sharpening, setting the height-of-cut or
performing other maintenance procedures on the cutting
units, store the cutting unit reel motors in the support tubes
on the front of the frame to prevent damage to the hoses.
1. Remove the cutting units from the cartons. Assemble
and adjust them as listed in the cutting unit Operator’s
Manual. Use the gauge bar from the loose parts kit to
adjust the height of cut.
2. Mount a washer and ball stud to each end of the front
roller on the cutting units (Fig. 10).
5. Mount the baskets on the pull frames, loosen the jam
nuts on the pull arms, and adjust the ball sockets until
there is 1/4 to 1/2 in. (6 to 13 mm) clearance between
the lip of the basket and the reel blades or the front
shield.
Note: This prevents the basket from tipping the cutting
unit forward, causing the lift roller to come off of the
lift arm while in the mowing operation.
Be sure the basket lip is equidistant from the reel blades
all across each reel. If the basket is too close to the reel,
it is possible for the reel to contact the basket when the
cutting unit is raised off of the ground.
6. Align the sockets in the ball joints so the open side of
the socket is centered towards the ball stud. Tighten the
jam nuts to secure the sockets in position (Fig. 12).
1
2
3
Figure 10
1. Pull frame
2. Pull arm
3. Ball stud
3. Slide the cutting unit under the pull frame while
hooking the lift hook onto the lift arm (Fig. 11).
1
2
Figure 11
1. Lift arm 2. Lift hook
4. Slide the sleeve back on the ball joint and rotate the pull
arm down so the socket fits over the ball stud. Release
the sleeve so it slides over the stud and locks the
assemblies together (Fig. 12).
1
3
2
Figure 12
1. Ball joint
2. Pull arm
3. Jam nut
7. Assemble the mounting capscrews for the reel drive
motor to each cutting unit. Leave approximately 1/2 in.
(13 mm) of threads exposed on each mounting
capscrew (Fig. 13).
1
2
Figure 13
1. Capscrews 2. Drive motor
8. Remove the protective covers from the cutting units and
the reel drive motor shafts.
15
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