Toro 30433 Operator's Manual

Download

Form No. 3350–738

Mid–Size Mower

ProLine Pistol Grip Hydro 15 HP with 36 inch Side Discharge Mower

Model No. 30433—Serial No. 250000001 and Up

Operator’s Manual

Original Instructions (EN)

Warning

CALIFORNIA

Proposition 65 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 This engine 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. 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 Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . .

Slope Chart 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 10. . . . . . . . . . . . . . .

Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .

Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .

Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Handle Assembly 15. . . . . . . . . . . . . .

Installing the Fuel Tank 15. . . . . . . . . . . . . . . . . . . .

Installing the Control Rods 16. . . . . . . . . . . . . . . . .

Installing the Speed Control Rod 17. . . . . . . . . . . . .

Installing the Hairpin Cotter Pins and Washers 17. .

W 2005 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Checking the Tire Pressure 17. . . . . . . . . . . . . . . . .

Checking the Hydraulic Fluid and Engine Oil 18. .

Setting Up the Hydro Linkage 18. . . . . . . . . . . . . . .

Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 18. . . . . . . . . . . . . . . . . . . . . . . .

Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 19. . . . . . . . . . . .

Operating Neutral Locks 20. . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 20. . . . . . . . . . . . . . . .

Operating Mower Blade Control (PTO) 21. . . . . . .

The Safety Interlock System 21. . . . . . . . . . . . . . . .

Driving Forward or Backward 22. . . . . . . . . . . . . . .

Bringing Machine to Neutral Position 22. . . . . . . . .

Stopping the Machine 22. . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 22. . . . . . . . . . . . . . .

Transporting Machines 23. . . . . . . . . . . . . . . . . . . .

Side Discharge or Mulch Grass 23. . . . . . . . . . . . . .

Adjusting the Height-of-Cut 23. . . . . . . . . . . . . . . .

Adjusting the Center Gage Wheels 24. . . . . . . . . . .

Adjusting the Handle Height 25. . . . . . . . . . . . . . . .

Using the Mid–Size Weight Kit 25. . . . . . . . . . . . . .

Maintenance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 26. . . . . . . .

Servicing the Air Cleaner 27. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 28. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 29. . . . . . . . . . . . . . . . . . .

Fuse Service 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 30. . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 31. . . . . . . . . . . . . . .

Checking the Tire Pressure 31. . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 32. . . . . . . . . . . . . . .

Servicing the Fuel Tank 32. . . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 33. . . . . . . . . . . . . . . . . . .

Servicing the Hydraulic System 33. . . . . . . . . . . . .

Hydraulic Linkage Adjustments 35. . . . . . . . . . . . .

Adjusting the Speed Control Linkage 35. . . . . . . . .

Temporary Neutral Stud Adjustment 37. . . . . . . . . .

Adjusting the Hydro Control Linkages 37. . . . . . . .

Adjusting the Neutral Stud 39. . . . . . . . . . . . . . . . .

Adjusting the Control Rod 40. . . . . . . . . . . . . . . . . .

Tracking Adjustment 41. . . . . . . . . . . . . . . . . . . . . .

Servicing the Brake 41. . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Electric Clutch 42. . . . . . . . . . . . . . .

Servicing the Cutting Blades 42. . . . . . . . . . . . . . . .

Correcting the Mower Quality of Cut 44. . . . . . . . .

Frame Set Up 44. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Deck Front-to-Rear Pitch 46. . . . . . .

Changing the Deck Front-to-Rear Pitch 46. . . . . . .

Checking the Deck Side-to-Side Leveling 47. . . . .

Printed in the USA

Page

Changing the Side-to-Side Leveling 47. . . . . . . . . .

Matching Height of Cut 47. . . . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 47. . . . . . . . . . . . . . . . . .

Replacing the PTO Drive Belt 48. . . . . . . . . . . . . . .

Replacing the Caster Wheel Fork Bushings 49. . . .

Caster Wheel and Bearings Service 49. . . . . . . . . . .

Replacing the Grass Deflector 50. . . . . . . . . . . . . . .

Wiring Diagram 51. . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Diagram 52. . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 53. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 56. . . . . . . . . . . . .

Introduction

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.

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.

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.

Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

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. mechanical information and Note: emphasizes general information worthy of special attention.

Important calls attention to special

Safety

Note: The addition of attachments made by other manufacturers that do not meet American National Standards Institute certification will cause noncompliance of this machine.

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 symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

m–6612

1. Location of the model and serial numbers

Write the product model and serial numbers in the space below:

Model No.

Serial No.

Figure 1

Safe Operating Practices

The following instructions are from ANSI standard B71.4—1999.

Training

• Read the Operator’s Manual and other training material. If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to himself or herself, other people or property.

Preparation

• 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.

• Wear appropriate clothing including hard hat, safety glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and remove all objects such as rocks, toys and wire which can be thrown by the machine.

• Use extra care when handling gasoline and other fuels. They are flammable and vapors are explosive.

• Use only an approved container

• Never remove gas cap or add fuel with engine

running. Allow engine to cool before refueling. Do not smoke.

• Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety

switches and shields are attached and functioning properly. Do not operate unless they are functioning properly.

Operation

• Never operate with the discharge deflector raised, removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed the engine.

• Stop on level ground, disengage drives, engage parking brake (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

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

• Keep hands and feet away from the cutting unit.

• Look behind and down before backing up to be sure of

a clear path.

• Keep pets and bystanders away.

• Slow down and use caution when making turns and

crossing roads and sidewalks. Stop blades if not mowing.

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

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

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

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

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is engaged before starting engine. Only start engine from the operator’s position.

• Be sure of your footing while using this machine, especially when backing up. Walk, don’t run. Never operate on wet grass. Reduced footing could cause slipping.

• Slow down and use extra care on hillsides. Be sure to travel side to side on hillsides. Turf conditions can affect the machine’s stability. Use caution while operating near drop-offs.

• Slow down and use caution when making turns and when changing directions on slopes.

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other guards not

securely in place. Be sure all interlocks are attached, adjusted properly, and functioning properly.

Maintenance and storage

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

• Clean grass and debris from cutting unit, drives, mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near flame.

• Shut off fuel while storing or transporting. Do not store fuel near flames or drain indoors.

• Park machine on level ground. Set parking brake. Never allow untrained personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with

stored energy.

• Remove spark plug wire before making any repairs.

• Use care when checking blades. Wrap the blade(s) or wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Use only Toro-approved attachments. Warranty may be voided if used with unapproved attachments.

• Keep hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

Toro Mower Safety

The following list contains safety information specific to Toro products and other safety information you must know.

This product is capable of amputating hands and feet and throwing objects. Always follow all safety instructions to avoid serious injury or death.

This product is designed for cutting and recycling grass or, when equipped with a grass bagger, for catching cut grass. Any use for purposes other than these could prove dangerous to user and bystanders.

General Operation

• Allow only responsible adults who are familiar with the instructions to operate the machine.

• Be sure the area is clear of other people before mowing. Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely necessary. Always look down and behind before and while backing.

• Be aware of the mower discharge direction and do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any terrain may cause loss of control.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away from

attachment discharge area, underside of mower and any moving parts while engine is running.

• Stop the engine before removing the grass catcher or unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

Slope Operation

Slopes and ramps are a major factor related to loss-of-control and accidents, which can result in severe injury or death. All slopes and ramps require extra caution. If you feel uneasy on a slope, do not mow it.

• Remove obstacles such as rocks, tree limbs, etc. from the mowing area.

• Watch for holes, ruts or bumps. Tall grass can hide obstacles.

• Use slow speed so that you will not have to stop while on the slope.

• Use extra care with grass catchers or other attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires lose traction, disengage the blades.

• Check carefully for overhead clearances (i.e. branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Mow slopes side to side.

DO NOT

• Do not mow slopes greater than 15 degrees.

• Avoid turning on slopes. If you must turn, turn slowly

and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or embankments. The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could cause sliding.

• Do not use a grass catcher on steep slopes. Heavy grass bags could cause loss of control of the machine.

• Do not mow up and down slopes.

Service

• Never store the machine or fuel container inside where there is an open flame, such as near a water heater or furnace.

• Keep nuts and bolts tight, especially the blade attachment bolts. Keep equipment in good condition.

• Never tamper with safety devices. Check safety systems for proper operation before each use.

• Use only genuine replacement parts to ensure that original standards are maintained.

• Check brake operation frequently. Adjust and service as required.

• Hydraulic fluid escaping under pressure can penetrate the skin and cause injury. Use cardboard or paper to find hydraulic leaks. Never use your hands.

Slope Chart

Example: Compare

slope with folded

edge.

Fold along appropriate line

Align this edge with a vertical surface

(Tree, Building, Fence post, pole, etc.)

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.

1-523552

68-8340

43-8480

66-1340

67-5360

93-1122

95-2814

98-0776

98-4387

1. Warning—wear hearing protection.

104-2838

106-5532

106-0699

104-8185

105-4110

105-4146

106-5512

105-4109

1. Keep bystanders a safe distance from the machine.

2. Do not allow bystanders to be hit by thrown objects.

3. Do not operate the mower with the deflector up or removed.

106-0635

106-5515

4. Stop the engine and pick up debris before operating.

5. Cutting of hand or foot, mower.

6. Engine—stop

7. Engine—run

8. Hour meter

9. To drive forward, move the controls as illustrated.

10. To place the machine in neutral, move the controls as illustrated.

11. To drive in reverse, move the controls as illustrated.

12. Power take-off (PTO)

13. Fast

14. Continuous variable setting

15. Slow

16. Neutral

106-5501

1. Choke 2. Fast 3. Continuous variable setting 4. Slow

Gasoline and Oil

Recommended Gasoline

Use UNLEADED Regular Gasoline suitable for automotive use (85 pump octane minimum). Leaded regular gasoline may be used if unleaded regular is not available.

Important Never use methanol, gasoline containing

methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Never fill the fuel tank inside an enclosed trailer.

• Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container and keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, remove gas–powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground.

• If this is not possible, then refuel such equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Warning

Gasoline is harmful or fatal if swallowed. Long–term exposure to vapors can cause serious injury and illness.

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel

system, which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol.

Add the correct amount of gas stabilizer/conditioner to the gas.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

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

2. Clean around fuel tank cap and remove the cap. Add

unleaded regular gasoline to fuel tank, until the level is 1/4 to 1/2 inch below the bottom of the filler neck. This space in the tank allows gasoline to expand. Do not fill the fuel tank completely full.

3. Install fuel tank cap securely. Wipe up any gasoline that may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 28.

Setup

Note: Determine the left and right sides of the machine from the normal operating position.

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Step Description Qty. Use

3 4 5

Handle assembly

Flanged bolt 3/8 x 1 inch

Flanged bolt 3/8 x 1–1/4 inch

Flange nut 3/8 inch

Fuel tank with studs installed

Bolt, 5/16 x 7/8 inch

Lock washer, 5/16 inch

Washer, 5/16 inch

Spring

Hose clamp

E–ring 2 Installing the control rods

Cotter pin

Washer

Hairpin cotter pin 2

Installing the handle assembly

Installing the fuel tank

Installing the speed control rod

Installing the hairpin cotter pins and washers

6 7 8

No parts needed Checking the tire pressure

No parts needed 1

No parts needed 1 Setting up the hydro control linkage

Oil drain hose

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Registration card

Checking the hydraulic fluid and engine oil

Use for draining engine oil

Read before operating machine

Fill out and return to Toro

Step

Parts needed for this step:

• 1 Handle assembly

• 2 Flange bolts, 3/8 x 1 inch

• 2 Flange bolts, 3/8 x 1–1/4 inch

• 4 Flange nuts, 3/8 inch

Installing the Handle Assembly

1. Align handle with upper mounting holes in rear frame (Fig. 2).

2. Secure the handle at each upper mounting hole with a flange bolt (3/8 x 1–1/4 inch) and flange nut (Fig. 2).

3. Select the low position for the lower mounting hole (Fig. 2).

4. Secure the handle at each lower mounting hole with a flange bolt (3/8 x 1 inch) and flange nut (Fig. 2).

Note: The handle position can be adjusted to match the operator’s height preference.

Parts needed for this step:

• 1 Fuel tank with studs installed

• 2 Bolts, 5/16 x 7/8 inch

• 2 Lock washers, 5/16 inch

• 2 Flat washers, 5/16 inch

• 2 Springs

• 1 Hose clamp

Installing the Fuel Tank

1. Align the fuel tank with the top of the rear frame (Fig. 4).

2. Push the fuel line through the grommet and hole in the hydraulic oil filter bracket (Fig. 4).

3. Push the fuel line onto the fuel tank connection and secure it with the hose clamp that is on the fuel line (Fig. 3).

Note: To ease assembly of the fuel line to fuel tank connection, apply a light lubricant, such as WD 40, to the end of the fuel line.

Note: Make sure the fuel line and clamp are on as shown in Figure 3.

Figure 2

1. Handle assembly

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

5. Upper mounting hole

Note: Handle assembly must be installed before fuel tank is installed.

6. Lower mounting holes

7. Low position

8. High position

9. Flange bolt, 3/8 x 1–1/4 inch

m–6600

Figure 3

1. Fuel line

2. Clamp

4. Secure the right side of the fuel tank to the rear frame (Fig. 4) with 2 bolts (5/16 x 7/8 inch), lock washers (5/16 inch) and washers (5/16 inch) (Fig. 4).

5. Secure the left side of the fuel tank to the rear frame (Fig. 4) with washers (5/16 inch), springs and locknuts (5/16 inch) (Fig. 4).

3. Fuel tank connection

m–6504

Note: Tighten left side of the gas tank until it is completely tight and then unscrew the locknut one full turn. This will allow the spring to work.

Step

Parts needed for this step:

• 2 E–clips

1. Bolt, 5/8 x 7/8 inch

2. Lock washer, 5/16 inch

3. Washer, 5/16 inch

4. Spring

Figure 4

5. Locknut

6. Hose clamp

7. Fuel tank connection

8. Grommet

m–6640

Installing the Control Rods

1. For a starting point, make sure the rod fittings are threaded approximately 2–1/2 inches (63 mm) onto the control rods (Fig. 5).

2. Install the rod fittings into the and secure them with E–rings (Fig. 5).

m–6601

1. Control rod

2. Rod fitting

Figure 5

3. 2–1/2 inch (63.5 mm) from bottom

4. E–ring

Step

Parts needed for this step:

• 1 Cotter pin

• 1 Washer

Installing the Speed Control Rod

1. Install the swivel into the speed control crank and secure it with a washer and cotter pin (Fig. 6).

Note: If necessary move the speed control lever until the swivel will go into the speed control crank.

Parts needed for this step:

• 2 Hairpin cotter pins

Installing the Hairpin Cotter Pins and Washers

Unused height–of–cut spacers may be stored on posts and retained by a hairpin cotter.

1. On the opposite side of the muffler, install unused washers and hairpin cotter pins into front and rear height–of–cut pins (Fig. 7).

1. Speed control rod

2. Swivel

3. Nut

Figure 6

4. Speed control crank

5. Cotter pin

6. Washer

m–6602

Figure 7

1. Hairpin cotter

2. Unused spacers

Step

3. Height–of–cut post

No parts needed for this step.

Checking the Tire Pressure

Refer to Page 31 for the correct correct tire pressure.

m-6505

Step

Checking the Neutral Stud

Refer to Adjusting the Neutral Stud on page 39.

No parts needed for this step.

Checking the Hydraulic Fluid and Engine Oil

Check the hydraulic fluid level before the engine is first started.

Refer to Checking the Hydraulic Fluid on page 33.

Check the engine oil level before the engine is first started.

Refer to Checking the Engine Oil Level on page 28.

Step

Checking the Control Rods

Refer to Adjusting the Control Rods on page 40.

Checking the Tracking

Refer to Adjusting Tracking on page 41.

Operation

Note: Determine the left and right sides of the machine from the normal operating position.

Think Safety First

Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

The use of protective equipment for eyes, hearing, feet and head is recommended.

Caution

No parts needed for this step.

Setting Up the Hydro Linkage

Check the following adjustments when the machine is first set up and adjust only as needed. Do them in the order that they are listed here.

Checking the Speed Control Linkage

Refer to Adjusting the Speed Control Linkage on page 35.

Checking the Neutral Control Linkages

Refer to Adjusting Neutral Control Linkages on page 37.

Checking the Hydro Control Linkages

Refer to Adjusting the Hydro Control Linkages on page 37.

This machine produces sound levels in excess of 85dBA at the operator’s ear and can cause hearing loss through extended periods of exposure.

Wear hearing protection when operating this machine.

Figure 8

1. Caution 2. Wear hearing protection

Controls

Become familiar with all the controls (Fig. 9) before you start the engine and operate the machine.

Throttle control – The throttle control has three positions: Choke, Fast and Slow.

Operator Presence Control (OPC) levers – OPC levers are used in conjunction with deck engagement switch (PTO) to release blade brake and engage clutch to drive mower blades. Release OPC levers to disengage mower blades.

Blade control switch (PTO) – Pull switch used in conjunction with OPC levers to release blade brake and engage clutch to drive mower blades.

Speed control lever – This machine has a variable speed control with a neutral position. This controls and limits how fast the machine will travel.

Drive levers – Move the speed control lever to the desired forward speed, slowly release the drive levers to engage forward traction operation, and squeeze the drive levers to neutral or reverse. When moving forward, squeeze the right drive lever to turn right and the left drive lever to turn left.

Neutral lock – Squeeze drive levers back and rotate locks to the rear for neutral lock.

Ignition Switch – Key switch is used in conjunction with recoil starter. Switch has two positions: Run and Off.

Recoil Starter – Pull recoil starter handle to start engine.

Fuel Shut–off Valve – (Under fuel tank) Close fuel

shut–off valve when transporting or storing mower.

Hour Meter – Shows total hours that machine has been operated. This operates only when the mower blades are operating.

1. Throttle control

2. Operator Presence Control levers (OPC)

3. Blade control switch (PTO)

4. Drive lever

Figure 9

5. Neutral lock

6. Ignition switch

7. Handle

8. Speed control lever

9. Hour meter

10. Fuel shut–off valve

m–6638

The hour meter will flash 3 hours before and after a service interval.

The service intervals are set for the first 8 hours, every 100 hours there after and every 400 hours.

Note: Make sure maintenance is done at all recommended intervals shown in the Recommended Maintenance Schedule on page 26.

Starting and Stopping the Engine

Starting

1. Make sure spark plug wire(s) are installed on spark plug(s) and fuel valve is open.

2. Move the speed control lever to neutral, set the neutral locks and turn ignition key to Run.

3. Move the throttle control to the Choke position before starting a cold engine.

Note: A warm or hot engine usually does not require any choking. To start a warm engine, move throttle control to the Fast position.

4. Grasp recoil starter handle firmly and pull out until positive engagement results; then pull handle vigorously to start engine and allow rope to recoil slowly.

Important Do not pull recoil rope to its limit or let go

of the starter handle when rope is pulled out because rope may break or recoil assembly may be damaged.

2. Place thumbs on the upper part of the neutral locks and rotate them forward until in the forward slot (Fig. 11).

Stopping

1. Squeeze the drive levers to the Neutral position and set the neutral locks.

2. Let engine idle for 30 to 60 seconds before turning the ignition key Off.

3. Turn the ignition key to Off (Fig. 10).

m–6638

Figure 10

1. Throttle lever 2. Ignition key

6 8

1. Handle

2. Neutral lock

3. Neutral position

4. Drive lever

Figure 11

5. Full speed forward

6. Reverse position

7. Grip

8. Forward slot

m–6578

Operating the Parking Brake

Always set the parking brake when you stop the machine or leave it unattended. Before each use, check brake for proper operation.

Important Make sure fuel shut off valve is closed

before transporting or storing machine, as fuel leakage may occur. Before storing machine, pull wire off spark plug(s) to prevent possibility of accidental starting.

Operating Neutral Locks

Always set the neutral lock when you stop the machine. Set the parking brake if it is left unattended.

Setting the Neutral Lock

1. Squeeze the drive levers back to neutral position (Fig. 11).

2. Place thumbs on the upper part of the neutral locks and rotate them back (Fig. 11).

Releasing the Neutral Lock

1. Squeeze the drive levers back to the grip slightly (Fig. 11).

If the parking brake does not hold securely, an adjustment is required. Refer to Servicing the Brake on page 41.

Caution

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Setting the Parking Brake

1. Pull the brake handle rearward (Fig. 11).

Releasing the Parking Brake

1. Push the brake handle forward (Fig. 11).

Disengaging the Mower Blades (PTO)

m–6614

Figure 12

1. Parking brake lever (released position)

2. Parking brake lever (engaged position)

Operating Mower Blade Control (PTO)

The blade control switch (PTO) in conjunction with the Operator Presence Control (OPC) levers engage and disengage power to the electric clutch and mower blades.

Engaging the Mower Blades (PTO)

1. To engage the blade, press the Operator Presence Control (OPC) levers against handle grips (Fig. 13).

2. Pull blade switch (PTO) up and release while holding the OPC levers against handle grip.

1. Release Operator Presence Control (OPC) levers to disengage blades (Fig. 13).

The Safety Interlock System

Caution

If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury.

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the mower from starting unless:

• The blade control switch (PTO) is off.

• The speed control lever is in neutral.

The safety interlock system is designed to kill the engine when:

• The Operator Presence Control (OPC) levers are released while the speed control is out of neutral position and/or the mower is engaged.

• The speed control lever is shifted out of neutral without holding OPC levers.

1. Handle

2. Operator Presence Control levers (OPC)

Figure 13

3. Blade control switch

4. Drive Lever

(PTO)

• The blade control switch (PTO) is pulled on without

holding the OPC levers.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate

m–6638

as described, have an Authorized Service Dealer repair the safety system immediately.

1. Set the neutral locks and place speed control lever in neutral. Start the engine; refer to Starting and Stopping the Engine, page 19.

2. Without holding the Operator Presence Control (OPC) levers, pull the blade control switch (PTO) up. The

engine should kill.

3. With engine running, hold down the OPC levers. Pull

the blade control switch (PTO) up. The clutch should engage and the mower blades begin rotating.

4. Release the OPC levers. The engine should kill.

5. With the engine running, move the speed control lever

forward. Release the OPC levers. The engine should kill.

Bringing Machine to Neutral Position

6. If all the above conditions are not met have an Authorized Service Dealer repair the safety system immediately.

Driving Forward or Backward

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.

Forward

1. Release the parking brake; refer to Releasing the Parking Brake, page 20.

2. To go forward, move the speed control lever to desired speed.

3. Release the neutral lock. Refer to Releasing the Neutral Lock on page 20.

4. Slowly release the drive levers to move forward (Fig. 14).

To go straight, release drive levers equally (Fig. 14).

To turn, squeeze the drive lever on the side and direction you want to turn (Fig. 14).

Always set the neutral lock when you stop the machine. Set the parking brake if it is left unattended.

1. Squeeze the drive levers back toward the grips to neutral position.

2. Set the neutral locks. Refer to Operating Neutral Locks on page 20.

3. Move speed control lever to neutral position.

Stopping the Machine

1. To stop the machine, squeeze the drive levers to the neutral position.

2. Rotate the neutral locks into the neutral lock position. Refer to Operating Neutral Locks on page 20.

3. Move the speed control lever into neutral.

4. Turn the ignition key to Off.

5. Set the parking brake if it is left unattended.

Note: Remember to remove the key from the ignition

switch if you leave the machine.

Caution

Figure 14

1. Drive lever 2. Speed control lever

Backward

1. Release the neutral lock. Refer to Releasing the Neutral Locks on page 20.

2. Slowly squeeze the drive levers back to the grips together to move rearward (Fig. 14).

m–663

Children or bystanders may be injured if they move or attempt to operate the machine while it is unattended.

Always remove the ignition key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Pushing the Machine by Hand

The by–pass valve allows the machine to be pushed by hand with the engine not running for easier servicing.

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

To Push the Machine

1. Move the speed control lever to neutral.

2. Disengage the power take off (PTO) by releasing the

OPC levers and turn the ignition key to Off.

3. Open the by-pass valves, by turning them counter clockwise 1 to 2 turns, to push the machine. This allows hydraulic fluid to by-pass the pump and the wheels to turn (Fig. 15).

Important Rotate by-pass valve a maximum of 2 turns

so the valve does not come out of the body causing fluid to run out.

To Operate the Machine

To operate the machine, ensure the by–pass valves are closed.

Note: The machine will not drive unless by-pass valves are closed.

Side Discharge or Mulch Grass

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

Danger

Without the grass deflector, discharge cover, or complete grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris. Contact with rotating mower blade(s) and thrown debris will cause injury or death.

• Never remove the grass deflector from the

mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

blades unless you release the bail and the power take off (PTO) is off. Rotate the ignition key to Off. Also remove the key and pull the wire off the spark plug(s).

m–6576

Figure 15

1. By-pass valve

Transporting Machines

Use a heavy-duty trailer or truck to transport the machine. Ensure that the trailer or truck has all necessary lighting and marking as required by law. Please carefully read all the safety instructions. Knowing this information could help you, your family, pets or bystanders avoid injury.

To transport the machine:

• Set the parking brake.

• Securely fasten the machine to the trailer or truck with

straps, chains, cable, or ropes.

• Secure a trailer to towing vehicle with safety chains.

Adjusting the Height-of-Cut

The height-of-cut can be adjusted from 1 to 4-1/2 inch (25 to 115 mm) in 1/4 inch (6 mm) increments. Adjustment is done by relocating four hairpin cotter pins in different hole location and by adding or removing spacers.

Note: Rear height–of–cut pins need at least one spacer or damage can occur to bushing if none are used.

1. To adjust, remove hairpin cotter from height-of-cut post (Fig. 16).

2. Select hole in height-of-cut post corresponding to the height-of-cut desired (Fig. 16).

3. Lift on side of deck and remove hairpin cotter (Fig. 16).

4. Add or remove spacers if needed and then align holes and insert hairpin cotter (Fig. 16).

Note: Spare height–of–cut spacers may be stored on posts and retained by a hairpin cotter.

Important All four hairpin cotter pins must be in the

same hole location and with the correct number of spacers for a level cut.

1. Carrier Frame

2. Hairpin Cotter

3. Front height–of–cut post

m–5230

Figure 16

4. Spacers

5. Back height–of–cut post

m–6366

Figure 17

m-4856

1. Center Gage Wheels and Spacer

2. Nut

3. Bolt

4. Washer

Adjusting the Center Gage Wheels

The gage wheels need to be adjusted in the proper hole location for each height-of-cut position. There needs to be 3/8 inch (10 mm) minimum clearance above the ground.

1. After adjusting height-of-cut, check the gage wheels so that there is a minimum of 3/8 inch (10 mm) clearance above the ground (Fig. 17).

2. If adjustment is needed, remove the bolt, washers and nut (Fig. 17).

3. Select a hole position so the gage wheels are a minimum of 3/8 inch (10 mm) off the ground (Fig. 17).

4. Install the bolt, washers and nut (Fig. 17).

Adjusting the Handle Height

The handle position can be adjusted to match the operator’s height preference.

Note:

1. Remove the hairpin cotter pin and clevis pin from the

drive lever and neutral lock (Fig. 18).

4. Remove the lower flange bolts (3/8 x 1 inch) and flange nuts securing handle to rear frame (Fig. 20).

5. Pivot handle to desired operating position and install lower flange bolts (3/8 x 1 inch) and flange nuts into mounting holes. Tighten all flange bolts.

m–6639

Figure 18

1. Left handle shown

2. Neutral lock

3. Clevis pin

4. Drive lever

5. Control rod

6. Operator Presence Control lever (OPC)

7. Hairpin cotter

2. Loosen the nuts holding the swivel connected to the speed control crank (Fig. 19).

m–6600

Figure 20

1. Handle assembly

2. Rear frame

3. Flange nut, 3/8 inch

4. Flange bolt, 3/8 x 1 inch

5. Upper mounting hole

6. Lower mounting holes

7. Low position

8. High position

9. Flange bolt, 3/8 x 1–1/4 inch

6. Adjust the swivel on the speed control rod and tighten the nuts against the swivel (Fig. 19).

7. Adjust the control rod length by rotating the control rod in the rod fitting (Fig. 5).

8. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Fig. 18).

m–6602

Figure 19

1. Speed control rod

2. Swivel

3. Nut

4. Speed control crank

5. Cotter pin

6. Washer

3. Loosen the upper flange bolts (3/8 x 1 inch) and flange nut securing handle to rear frame (Fig. 20).

Note: Make sure the clevis pins are inserted into the neutral locks.

9. Perform the hydraulic linkage adjustments when the handle height is changed. Refer Hydraulic Linkage Adjustments on page 35.

Using the Mid–Size Weight Kit

A weight kit is available for this machine. This kit is optional and can be obtain from an Authorized Service Dealer.

Installing this weight kit can improve performance on slopes.

Note: For this machine, install the weight kit only in the front position.

Note: The use of a Tru–TrakR Sulky on this machine is not recommended.

Maintenance

Note: Determine the left and right sides of the machine from the normal operating position.

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

After first 8 Hours • Hydraulic Oil—check

8 Hours

25 Hours • Foam Air Cleaner—clean

40 Hours

50 Hours • Belts—check

100 Hours

Maintenance Procedure

• Oil—check level

• Safety System—check

• Brake—check

• Engine—clean outside

• Mower Housing—clean

• Caster Wheels—grease

• Caster Pivot—grease

• Cutting Blades—check

• Hydraulic Oil—check

• Tires—check pressure

• PTO Belt Idler Arm—grease

• Oil—change

• Spark Plug(s)—check

• Electric Clutch—adjust

• Engine—clean outside

• Paper Air Cleaner—replace

• Hydraulic lines—check

After first 200 Hours • Hydraulic oil filter—change

200 Hours

At storage

More often in dusty, dirty conditions.

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

• Fuel Filter—replace

• Oil Filter—change (200 hours or every other oil change)

• Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

Caution

If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders.

Remove the key from the ignition and disconnect the spark plug wire from the spark plug(s) before you do any maintenance. Set the wire aside so that it does not accidentally contact the spark plug.

Servicing the Air Cleaner

Service Interval/Specification

Foam Element: Clean and re-oil after every 25 operating hours.

Paper Element: Replace after every 100 operating hours.

Inspect the foam and paper elements, and replace them if they are damaged or excessively dirty.

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

Note: Excess oil in the foam element restricts the air flow through the element and may reach the paper filter and clog it.

Important Replace the foam element if it is torn or

worn.

Removing the Foam and Paper Elements

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Clean around the air cleaner to prevent dirt from getting into the engine and causing damage. Unscrew the cover nut and remove the air cleaner cover (Fig. 21).

3. Remove the air cleaner assembly (Fig. 21).

4. Carefully slide the foam element off the paper element

(Fig. 21).

m–5193

Figure 22

1. Foam element 2. Oil

Inspecting the Paper Element

Important Never clean the paper element with

pressurized air or liquids, such as solvent, gas, or kerosene.

1. Inspect the element for tears, an oily film, and damage to the rubber seal (Fig. 23).

2. Replace the paper element if it is damaged or excessively dirty.

m–2595

Figure 21

1. Cover and nut

2. Wing nut

3. Foam element

4. Washer and grommet

5. Paper element

6. Air cleaner base

Cleaning the Foam Elements

1. Wash the foam element in liquid soap and warm water. When the element is clean, rinse it thoroughly.

2. Dry the element by squeezing it in a clean cloth.

3. Put one or two ounces of oil on the element (Fig. 22).

Squeeze the element to distribute the oil.

m–5192

Figure 23

1. Paper element 2. Rubber seal

Installing the Foam and Paper Elements

Important To prevent engine damage, always operate

the engine with the complete foam and paper air cleaner assembly installed.

1. Installing the Foam and Paper Elements

1. Carefully slide the foam element onto the paper air

cleaner element (Fig. 21).

2. Place the air cleaner assembly onto the air cleaner base (Fig. 21).

3. Install the air cleaner cover and secure with cover nuts (Fig. 21).

Servicing the Engine Oil

Service Interval/Specification

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when operating conditions are extremely dusty or sandy.

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

Crankcase Capacity: w/filter, 64 oz. (1.9 l)

Viscosity: See table below

USE THESE SAE VISCOSITY OILS

10W–30

5W–20, 5W–30

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

Checking the Oil Level

1. Park the machine on a level surface, disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

Figure 24

1. Oil dipstick

2. Metal end

3. Filler tube

Changing the Oil

1. Start the engine and let it run five minutes. This warms the oil so it drains better.

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

3. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

4. Slide the drain hose over the drain valve.

5. Place a pan below the drain hose. Rotate the drain

valve to allow the oil to drain (Fig. 25).

6. When the oil has drained completely, close the oil drain valve and remove the drain hose (Fig. 25).

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

2. Clean around the oil dipstick (Fig. 24) so dirt cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean (Fig. 24).

4. Slide the oil dipstick fully into the filler tube, do not thread onto tube (Fig. 24). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

Figure 25

1. Oil drain valve 2. Oil drain hose

m-6511

7. Slowly pour approximately 80% of the specified oil into the filler cap (Fig. 24). Refer to Servicing the Engine Oil, page 28.

8. Check the oil level; refer to Checking the Oil Level, page 28.

9. Slowly add additional oil to bring it to the full mark.

Changing the Oil Filter

Servicing the Spark Plug

Service Interval/Specification

Check the spark plug(s) after every 200 operating hours. Make sure 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(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Service Interval/Specification

Replace the oil filter every 200 hours or every other oil change.

Note: Change oil filter more frequently when operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to Changing the Oil, page 28.

2. Remove the old filter and wipe the filter adapter (Fig. 26) gasket surface.

3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 26).

m–1256

Figure 26

1. Oil filter

2. Gasket

3. Adapter

Type: Championr RC12YC or Championr Premium Gold 2071 (or equivalent)

Air Gap: 0.040 in. (1.02 mm)

Removing the Spark Plug(s)

1. Disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 27). Now clean around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

3. Remove the spark plug(s) and metal washer.

Figure 27

1. Spark plug wire 2. Spark plug

m–4757

4. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 26).

5. Fill the crankcase with the proper type of new oil; refer to Changing the Oil, page 28.

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 28). 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.

Important Never clean the spark plug(s). Always

replace the spark plug(s) when it has: a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side electrodes (Fig. 28). Bend the side electrode (Fig. 28) if the gap is not correct.

1. Center electrode insulator

2. Side electrode

Figure 28

3. Air gap (not to scale)

0.040 in.

(1.02 mm)

Figure 29

1. Fuse, 10 amp

Greasing and Lubrication

Service Interval/Specification

m–5391

m–5390

Installing the Spark Plug(s)

1. Install the spark plug(s) and metal washer. Make sure the air gap is set correctly.

2. Tighten the spark plug(s) to 20 ft-lb (27 N.m).

3. Push the wire(s) onto the spark plug(s) (Fig. 27).

1. Lubricate the front wheel bearings and front spindles

until grease begins to ooze out of the bearings (Fig. 31).

Fuse Service

Service Interval/Specification

The electrical system is protected by a fuse. It requires no maintenance. If the fuse blows check component or circuit for malfunction or short. To replace the fuse, pull out the existing fuse (Fig. 29) and push in the new fuse.

Fuse: F1– 10 amp, blade-type

Grease with No. 2 general purpose lithium base or molybdenum base grease.

How to Grease

1. Disengage the PTO and set the parking brake.

2. Stop 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. Make sure to scrape any paint off the front of the fitting(s).

4. Connect a grease gun to the fitting. Pump grease into the fittings until grease begins to ooze out of the bearings.

5. Wipe up any excess grease.

Where to add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 30).

Figure 30

m–7905

Figure 32

Cleaning the Cooling System

Lubricating the Caster Bearings

1. Lubricate the front wheel bearings and front spindles until grease begins to ooze out of the bearings (Fig. 31).

m–636

Figure 31

Greasing the PTO Drive Belt Idler and Deck Belt Idler

1. Stop the engine, set the parking brake, remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Service Interval/Specification

Before each use, check and clean engine cooling system. Remove any build–up of grass, dirt or other debris from the cylinder and cylinder head cooling fins, air intake screen on flywheel end, and carburetor–governor levers and linkage. This will help insure adequate cooling and correct engine speed and will reduce the possibility of overheating and mechanical damage to the engine.

Checking the Tire Pressure

Service Interval/Specification

Maintain the air pressure in the front and rear tires as specified. Check the pressure at the valve stem after every 40 operating hours or monthly, whichever occurs first (Fig. 33). Check the tires when they are cold to get the most accurate pressure reading.

Rear Tire Pressure: 12–14 psi (83–97 kPa)

Caster Tire Pressure: 25–30 psi (172–207 kPa)

Greasing the PTO Drive Belt Idler

1. Grease the fitting on the PTO belt idler arm pivot (Fig. 32).

Figure 33

1. Rear Tire 2. Caster tire

m–6367

Servicing the Fuel Tank

Danger

In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property.

• Drain gasoline from the fuel tank when the engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay away from an open flame or where a spark may ignite the gasoline fumes.

Adjusting the Electric Clutch

The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation.

1. To adjust clutch, tighten or loosen lock nuts on flange studs (Fig. 34).

2. Check adjustment by inserting feeler gauge thru slots next to studs (Fig. 34).

3. The proper disengaged clearance between the clutch plates is 0.012–0.018 inch (0.30-0.45 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

Draining the Fuel Tank

1. Park the machine on a level surface, to assure fuel tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 35).

3. Squeeze the ends of the hose clamp together and slide

it up the fuel line away from valve (Fig. 35).

4. Pull the fuel line off the valve (Fig. 35). Open fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty. Refer to Replacing the Fuel Filter; page 33.

5. Install the fuel line onto the valve. Slide the hose clamp close to the valve to secure the fuel line.

1. Adjusting nut

2. Slot

Figure 34

3. Feeler gauge

m–2600

m–5235

Figure 35

1. Fuel shut-off valve 2. Clamp

Servicing the Fuel Filter

Servicing the Hydraulic

Service Interval/Specification

Replace the fuel filter after every 200 operating hours or yearly, whichever occurs first.

Replacing the Fuel Filter

Never install a dirty filter if it is removed from the fuel line.

Note: Note how the fuel filter is installed.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Close fuel shut–off valve at the fuel tank (Fig. 35).

Note: Remove fuel line from fuel valve that is closest to

the engine.

4. Squeeze the ends of the hose clamps together and slide them away from the filter (Fig. 36).

5. Remove the filter from the fuel lines.

6. Install a new filter and move the hose clamps close to

the filter.

7. Open fuel shut-off valve at the fuel tank (Fig. 35).

8. Check for fuel leaks and repair if needed (Fig. 36).

System

Checking the Hydraulic Fluid

Check the hydraulic fluid level before engine is first started.

Check the hydraulic fluid level after first 8 operating hours.

Check the hydraulic fluid level after every 40 operating hours.

Fluid Type: Mobil 1 15W-50 synthetic motor oil or equivalent synthetic oil.

Important Use oil specified or equivalent. Other

fluids could cause system damage.

Hydraulic System Oil Capacity: 67 oz. (2.0 l)

Note: There are two ways of checking the hydraulic oil. One is when the oil is warm and one is when the oil is cold. The baffle inside the tank has two levels depending if the oil is warm or cold.

1. Position machine on a level surface and set the parking brake.

2. Clean area around filler neck of hydraulic tank (Fig. 37).

3. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir. (Fig. 37).

4. If there is no fluid, add fluid to the reservoir until it reaches the cold level of the baffle.

5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm fluid. Refer to Starting and Stopping the Engine on page 19.

1. Hose clamp

2. Fuel line

Figure 36

3. Filter

6. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle.

Note: The fluid level should be to the top of the hot level

m–5234

of the baffle, when the fluid is warm (Fig. 37).

7. Install cap on filler neck.

3. Place drain pan under filter, remove the old filter and wipe the filter adapter gasket surface clean (Fig. 38).

Figure 37

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

Warning

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

m–5615

m–6575

Figure 38

1. Hydraulic filter

4. Apply a thin coat hydro fluid to the rubber gasket on the replacement filter (Fig. 39).

5. Install replacement hydraulic filter onto the filter adapter. Do not tighten.

6. Remove plastic bag from tank opening and allow filter to fill with hydro fluid.

7. When fluid overflows filter turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 39).

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 200 operating hours.

• Yearly, before storage.

1. Position machine on a level surface, stop the engine, and remove key from ignition switch.

Important Do not substitute automotive oil filter or

severe hydraulic system damage may result.

2. Remove hydro cap and temporarily cover opening with a plastic bag and rubber band to prevent all hydro fluid from draining out.

Figure 39

1. Hydraulic filter

2. Gasket

3. Adapter

8. If there is no fluid, add fluid to reservoir approximately a 1/4 inch (6 mm) below the top of baffle.

9. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 35.

m–1256

10. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Do not overfill.

Warning

Bleeding the Hydraulic System

The traction system is self bleeding, however, it may be necessary to bleed the system if fluid is changed or after work is performed on the system.

1. Raise rear of the machine so wheels are off the ground and support with jack stands.

2. Start the engine and run at idle speed. Engage traction on one side and spin the wheel by hand.

3. When the wheel begins to spin on its own, keep it engaged until wheel drives smoothly (minimum 2 minute).

4. Check hydraulic fluid level as it drops and add as required to maintain proper level.

5. Repeat procedure on opposite wheel.

Checking the Hydraulic Lines

After every 100 operating hours, check hydraulic lines and hoses for leaks, loose fittings, kinked lines, loose mounting supports, wear, weather and chemical deterioration. Make necessary repairs before operating.

Hydraulic fluid escaping under pressure can penetrate skin and cause injury.

• If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Hydraulic Linkage Adjustments

Perform the following linkage adjustments when the machine needs maintenance or set–up for the first time.

Note: Keep areas around hydraulic system clean from grass and debris build up.

Perform the steps Adjusting the Speed Control Linkage through Adjusting the Tracking. If adjustment is needed, do them in the order that they are listed.

Adjusting the Speed Control Linkage

1. Stop engine and wait for all moving parts to stop.

2. Move the speed control lever to the full forward

position (Fig. 40).

Side View

m–6477

Figure 40

1. Speed control lever

2. Full speed position

3. Neutral position

4. Medium speed position

5. Control panel

3. Check the orientation of the tabs on the ends of the speed control crank. These tabs should approximately be pointing straight down at the 6 o’clock position (Fig. 41).

4. If adjustment is needed, loosen the nuts on both sides of the swivel on the speed control rod (Fig. 41).

5. Adjust the swivel, until the tabs are at the 6 o’clock position (Fig. 41).

6. Tighten the nuts on both sides of the swivel (Fig. 41).

m–6607

Figure 41

1. Speed control rod

2. Nut

3. Speed control crank

4. Tabs in 6 o’clock position

5. Swivel

7. Pull the speed control lever back to neutral.

8. Check to make sure the safety switch is depressed and

there is an 1/8 to 1/4 inch (3 to 6 mm) space between the actuating tab and the safety switch (Fig. 42).

1. Actuating tab

2. 1/8 to 1/4 inch space

3. Neutral safety switch

m–6604

Figure 42

4. Neutral bracket

5. Neutral bracket screws

9. To adjust the switch location, loosen the two neutral bracket screws holding the switch plate to the frame (Fig. 42).

10. Adjust the switch up or down to obtain an 1/8 to 1/4 inch (3 to 6 mm) space (Fig. 42).

Adjusting the Hydro Control Linkages

Warning

11. Tighten the two neutral bracket screws holding the switch plate (Fig. 42).

Temporary Neutral Stud Adjustment

1. Move the left and righthand neutral lock latches to the unlatched position (Fig. 11).

2. Move the speed control lever to the neutral position (Fig. 40).

3. Loosen the nut against the yoke (Fig. 43).

4. Adjust the length of the neutral stud and yoke

assembly so the clevis pin does not contact the back of the slot in the control arm bracket (Fig. 43).

5. Tighten the nut against the yoke (Fig. 43).

Engine must be running so control linkage adjustments can be performed. Contact with moving parts or hot surfaces may cause personal injury.

Keep hands, feet, face, clothing and other body parts away from rotating parts, muffler and other hot surfaces.

Warning

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stands when supporting the machine.

• Do not use hydraulic jacks.

Adjusting the Left Side Hydro Control Linkage

Warning

1. Neutral control linkage

2. Yoke

3. Neutral stud

4. Nut

Figure 43

5. Slot in control arm bracket

6. Clevis pin

7. Clevis pin does not

m–6641

contact the back of slot

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence Control (OPC) levers held in place.

1. Raise the rear of the machine onto jack stands to raise

the drive wheels off the ground.

2. Start the engine and move the throttle ahead to the full throttle position.

3. Press and hold the OPC levers down.

Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

4. Place the left neutral lock in the full forward position (Fig. 50) and move the speed control lever to the neutral position (Fig. 40).

5. Loosen the front nut on left hydro control linkage shown in figure 45.

6. Turn the left rear adjusting nut counter–clockwise until wheel rotates forward (Fig. 45).

7. Turn the rear adjusting nut clockwise 1/4 of a turn at a time. Then move the speed control lever forward and back to neutral. Repeat this until left wheel stops rotating forward (Fig. 45).

Note: Make sure flat part of linkage is 90 degrees or perpendicular to pin part of swivel (Fig. 44).

8. Tighten the front nut on left hydro control linkage shown in figure 45.

Back View

90 Degrees

m–6606

Figure 44

1. Hydro control linkage

2. Swivel

3. Incorrect position

4. Correct position

m–6604

Figure 45

1. Hydro control linkage

2. Front nut

3. Rear adjusting nut

Note: If inconsistent neutral occurs, check to be sure both springs are properly tightened on the speed control lever under the console, especially the rear pivot spring. Repeat above adjustments if necessary (Fig. 46).

9. After adjusting the left hydro control linkage, move the speed control lever forward and then back to the neutral position.

10. Make sure the speed control lever is in the neutral position and the tire does not rotate.

11. Repeat adjustment if needed.

m–5396

Figure 46

1. Speed control lever

2. Rear pivot spring

3. spring

Right Side Linkage Adjustment

1. With the machine on jack stands, place the speed control lever in the neutral position (Fig. 40).

2. Place the right drive lever in the full forward position (Fig. 50).

3. Hold the OPC levers down.

Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

4. Adjust the right side linkage by turning the quick track knob counterclockwise until the tire begins to rotate forward (Fig. 47).

5. Turn the knob clockwise 1/4 of a turn at a time. Then move the speed control forward and back to neutral. Repeat this until right wheel stops rotating forward (Fig. 47).

6. The spring that keeps tension on the knob should normally not need adjustment. However, if adjustment is needed, adjust the length of the spring to 1 inch (26 mm) between the washers (Fig. 47).

7. Adjust spring length by turning the nut at the front of the spring (Fig. 47).

8. After adjusting the right hydro control linkage, move the speed control lever forward and then back to the neutral position.

9. Make sure the speed control lever is in the neutral position and the tire does not rotate.

1. With the machine on jack stands, place the speed control lever in the neutral position (Fig. 40).

2. Hold the OPC levers down.

Note: The OPC levers must be held down whenever the

speed control lever is out of the neutral position or the engine will kill.

3. Adjust the left and right neutral stud until the clevis pin in the yoke touches the back end of the slot in the control arm (Fig. 48).

10. Repeat adjustment if needed.

3 2

m–6605

Figure 47

1. Hydro control linkage

2. Quick track knob

3. Spring

4. 1 inch (26 mm)

5. Nut in front of spring

Adjusting the Neutral Stud

Warning

m–6604

Figure 48

1. Neutral control linkage

2. Yoke

3. Neutral stud

4. Nut

5. Slot in control arm bracket

6. Clevis pin

7. Spring

8. Back end of slot

4. Move the speed control lever to the full forward position (Fig. 40).

5. Squeeze one drive lever until an increased resistance is felt (Fig. 50). This is neutral position. This is where the clevis pin in the yoke comes to the back end of the slot in the control arm bracket.

Note: Make sure you have not reached the end of the neutral lock slot (Fig. 50). If you have, shorten the control rod. Refer to Adjusting the Control Rod on page 40.

6. If the wheel turns while holding the drive lever in neutral position, the neutral stud needs to be adjusted (Fig. 43). If the wheel does not rotate, then go to step 12.

Electrical system will not perform proper safety shut off with Operator Presence Control (OPC) levers held in place.

• Make sure Operator Presence Control (OPC) levers are working when adjustment is completed.

• Never operate this unit with Operator Presence Control (OPC) levers held in place.

7. Loosen the nut against the yoke (Fig. 48).

8. Adjust the adjustment stud until the respective drive

wheel stops while holding the drive in neutral position (increase resistance) (Fig. 43).

9. Turn the adjusting bolt approximately 1/4 turn clockwise if the wheel is turning in reverse and turn the bolt approximately 1/4 turn counter–clockwise if the wheel is turning forward (Fig. 43).

10. Release the drive lever to the forward drive position and squeeze back into the neutral position (Fig. 50). Check to see if the wheel stops. If not, repeat steps 8 and 9.

11. After adjustments are made, tighten the nut against the yoke.

12. Repeat this procedure for the opposite side.

Adjusting the Control Rod

Checking the Control Rod

1. With rear of machine still on jack stands and engine running at full throttle, move the speed control lever to the medium speed position.

Note: The OPC levers must be held down whenever the speed control lever is out of the neutral position or the engine will kill.

2. Move the respective drive lever upward until it reaches the neutral position and engage neutral locks.

3. If the tire rotates in either direction, the length of the control rod will need to be adjusted.

Adjusting the Control Rods

1. Adjust the rod length by releasing the drive lever and removing the hairpin cotter pin and clevis pin (Fig. 49). Rotate the rod in the rod fitting (Fig. 50).

2. Lengthen the rod if the tire is turning in reverse and shorten the rod if the tire is turning forward.

3. Rotate the rod several turns if the tire is rotating fast. Then, adjust the rod in 1/2 turn increments.

4. Place the clevis pin in to the drive lever (Fig. 49).

m–6639

Figure 49

1. Left handle shown

2. Neutral lock

3. Clevis pin

4. Drive lever

5. Control rod

6. Operator Presence Control lever (OPC)

7. Hairpin cotter

5. Release and engage neutral lock checking that the tire does not rotate. Continue this process until the tire does not rotate.

6. Install hairpin cotter between drive levers and neutral locks and into clevis pins (Fig. 49).

Note: Make sure the clevis pins are inserted into the neutral locks.

7. Repeat this adjustment for opposite side.

m–6578

1. Handle

2. Neutral lock

3. Neutral position

4. Drive lever

Figure 50

5. Full speed forward

6. Control rod

7. Neutral lock slot

8. Grip

Tracking Adjustment

1. Remove the machine from any jack stands.

5. If there is a reasonable amount of force, no adjustment

is required.

2. Check the rear tire pressure. Refer to Checking the Tire Pressure Service on page 31.

3. Start and run the unit. Observe the tracking on a level, smooth, hard surface such as concrete or asphalt.

4. If the unit tracks to one side or the other, turn the quick track knob. Turn the knob right to steer right and turn the knob left to steer left (Fig. 51).

m–6603

Figure 51

1. Quick track knob

Adjusting the Brake

The brake handle is on the left side of machine (Fig. 52). If the parking brake does not hold securely, an adjustment is required.

1. Check the brake before you adjust it; refer to Checking the Brake, page 41.

2. Release the parking brake; refer to Releasing the Parking Brake, page 20.

3. Loosen the top and bottom jam nuts (Fig. 52).

4. To adjust the brake, remove the hair pin cotter and

clevis pin from the lower brake lever (Fig. 52).

5. Rotate the brake rod in the yokes. To tighten the brake, lengthen the rod between the yokes. To loosen the brake, shorten the rod between the yokes (Fig. 52).

Note: The brake rod should be threaded into both yokes the same distance.

6. Secure the yoke to lower brake lever with the hair pin cotter and clevis pin (Fig. 52).

7. Tighten the top and bottom jam nuts (Fig. 52).

8. Check the brake operation again; refer to Checking the

Brake, page 41.

Servicing the Brake

Service Interval/Specification

Before each use, check brake for proper operation.

Always set the parking brake when you stop the machine or leave it unattended. If the parking brake does not hold securely, an adjustment is required.

Checking the Brake

1. Park the machine on a level surface.

2. Disengage the PTO and set the parking brake.

3. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

4. To set the parking brake, it should take a reasonable amount of force. If it engages too hard or easily, adjustment is required. Refer to Adjusting the Brake on page 41.

Note: When the brake is engaged, the brake handle should be close to the 1 o’clock position.

1. Yoke

2. Parking brake lever (released position)

3. Clevis pin

4. Hairpin cotter

m–6614

Figure 52

5. Jam nut

6. Brake rod

7. Lower brake lever

8. 1 o’clock position

Adjusting the Electric Clutch

The clutch is adjustable to ensure proper engagement and proper braking. Check adjustment after every 100 hours of operation.

1. To adjust clutch, tighten or loosen lock nuts on flange studs (Fig. 53).

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Check adjustment by inserting feeler gauge through slots next to studs (Fig. 53).

3. The proper disengaged clearance between the clutch plates is 0.012–0.024 inch (0.30-0.60 mm). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

m–2600

Figure 53

1. Adjusting nut

2. Slot

3. Feeler gauge

Servicing the Cutting Blades

Inspecting the Blades

1. Inspect the cutting edges (Fig 54). If the edges are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 43.

2. Inspect the blades, especially the curved area (Fig. 54). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 54), immediately install a new blade.

m–151

1. Cutting Edge

2. Curved Area

Figure 54

3. Wear/slot Forming

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.

Warning

A worn or damaged blade can break, and a piece of the blade could be thrown into the operator’s or bystander’s area, resulting in serious personal injury or death.

• Inspect the blade periodically for wear or damage.

• Replace a worn or damaged blade.

Checking for Bent Blades

1. Rotate the blades until the ends face forward and backward (Fig. 55). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 56). Note this dimension.

Front

m–1078

Figure 55

MEASURE FROM CUT-

TING EDGE TO A LEV-

EL SURFACE

m–1087

Figure 56

2. Rotate the opposite ends of the blades forward.

3. Measure from a level surface to the cutting edge of the

blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 43.

Warning

m–6368

Figure 57

1. Sail Area of Blade

2. Blade

3. Blade spindle

4. Blade Bolt

5. Blade stiffener

6. Flat washer

Sharpening the Blades

1. Use a file to sharpen the cutting edge at both ends of the blade (Fig. 58). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 58

1. Sharpen at original angle

A blade that is bent or damaged could break apart and could seriously injure or kill you or bystanders.

• Always replace bent or damaged blade with a new blade.

• Never file or create sharp notches in the edges or surfaces of blade.

Removing the Blades

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine TORO replacement blades. Replacement blades made by other manufacturers may result in non-conformance with safety standards.

1. Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, blade stiffener, washer, and blade from the spindle shaft (Fig. 57).

2. Check the balance of the blade by putting it on a blade balancer (Fig. 59). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 57). Repeat this procedure until the blade is balanced.

Figure 59

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 57).

m–1855

Important The sail part of the blade must be pointing

upward, toward the inside of the mower to ensure proper cutting (Fig. 57).

2. Install the lock washer and blade bolt (Fig. 57).

Torque the blade bolt to 85–110 ft-lb (115–140 NSm).

Correcting the Mower Quality of Cut

If one deck blade cuts lower than the other, correct as follows.

Note: Tire air pressure is critical in these procedures.

Make sure all tires have correct pressure.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position. Disconnect the spark plug wire(s) from the spark plug(s).

3. Adjust the tire pressure in all tires to specifications on page 31.

4. Check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 42.

5. Set the height-of-cut to the 4 inch (101.6 mm) position. Refer to Adjusting the Height-Of-Cut in the Operation section.

6. Perform steps in the following sections Frame Set Up, Checking Front–to–Rear Pitch and Checking Side–to–Side Leveling.

4. At the carrier frame cross tube, measure location A height (Fig. 60). This measurement must be 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm).

5. If the height at location A is not correct, adjustment is needed.

6. Loosen the carrier frame mounting bolts on both sides of the machine (Fig. 60).

7. Align the carrier frame and engine deck to match 1–5/16 inch (33 mm), plus or minus a 1/4 inch (6 mm) at location A (Fig. 60).

8. Tighten the carrier frame mounting bolts on both sides of the machine.

m–6369

1. Carrier Frame

2. Top of engine deck

3. Carrier frame mounting bolts

Figure 60

4. Location A, 1–5/16 inch

5. Straight edge

6. Carrier frame cross tube

(33 mm) ±1/4 inch (6 mm)

Frame Set Up

Checking Carrier Frame and Deck Alignment

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Place a long straight edge on top of the engine deck as shown in figure 60.

Checking Engine Deck Height

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Adjust the tire pressure in all tires to specifications on page 31.

4. Measure engine deck height at location A (Fig. 61).

5. Measure engine deck height at location B (Fig. 61).

6. If the height at location A and B are not the same, change tire pressure slightly to make them the same.

444

Figure 61

1. Back view of machine

2. Top of engine deck

3. Tires

4. Same height at locations A and B

m–5237

24 in.

(61cm)

Figure 62

1. Caster Wheel

2. Carrier Frame

3. 1/4–3/8 inch (6 mm–10 mm) pitch over 24 inch (61 cm) length

4. Height at locations A and B

5. Caster spacers

Checking Carrier Frame Side–to–Side

m–6370

Checking Carrier Frame Front–to–Rear Pitch

The carrier frame must have a pitch of a 1/4 inch (6 mm) over the length of 24 inches (61 cm) on the carrier frame (Fig. 62).

1. Measure out 24 inches (61cm) on the carrier frame (Fig. 62).

2. Measure carrier frame height at location A (Fig. 62).

3. Measure carrier frame height at location B (Fig. 62).

4. The height at location A must be a 1/4–3/8 inch (6 mm –10 mm) lower than location B (Fig. 62).

5. If the carrier frame is not correct, move caster spacers

to make it a 1/4–3/8 inch (6 –10 mm) pitch (Fig. 62). Move spacers from top or bottom to make the correct pitch.

6. The tire pressure may also be adjusted slightly to make a 1/4 inch (6 mm) pitch.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Adjust the tire pressure in all tires to specifications on page 31.

4. Measure carrier frame height at location A (Fig. 63).

5. Measure carrier frame height at location B (Fig. 63).

6. If the carrier frame height is not the same move

spacers from top or bottom of caster wheel, to make it level. The tire pressure may also be adjusted slightly to make it level.

MEASURE FROM CUT-

TING EDGE TO A LEV-

EL SURFACE

m–1087

Figure 65

4 4

m–6371

Figure 63

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Same height at locations A and B

5. Caster spacers

Checking the Deck Front-to-Rear Pitch

1. Check the tire pressure on both deck and traction unit.

2. Position one blade front-to-rear (Fig. 64). Measure at C and D locations (Fig. 64) from a level surface to the

cutting edge of the blade tips (Fig. 65).

3. The mower blade should be 1/4 inch (6 mm) lower in front at C than in the rear at D. Rotate blades and

repeat for other blades. If it is not correct, proceed to Changing the Deck Front–to–Rear Pitch.

Front

Changing the Deck Front-to-Rear Pitch

Changing the front–to–rear pitch is done by adjusting the front height–of–cut posts.

Changing the Deck Front–to–Rear Pitch by Adjusting Front Height–of–Cut Posts

1. To change the front-to-rear pitch, the front height–of–cut posts can be adjusted (Fig. 66).

2. To raise the front of the deck, loosen jam nut and rotate the front pin clockwise (Fig. 66).

3. To lower the front of the deck, loosen jam nut and rotate the front pin counter clockwise (Fig. 66).

Figure 64

m–1078

m–6371

Figure 66

1. Caster Wheel

2. Carrier Frame

3. Front height–of–cut pins

4. Jam nut

5. Ball joint

4. Position the blades front-to-rear (Fig. 64). Measure at C and D locations (Fig. 64) from a level surface to the

cutting edge of the blades (Fig. 65).

5. Check the side-to-side leveling of the cutting unit.

Checking the Deck Side-to-Side Leveling

1. Check the tire pressure on both deck and traction unit.

2. Position the blades side-to-side (Fig. 67). Measure at A

and B locations (Fig. 67) from a level surface to the cutting edge of blade tips (Fig. 68).

3. The difference between measurements A and B should be no more than 1/4 inch (6 mm).

Front

2. Set the height-of-cut to the 4 inch (101.6 mm) position following the height-of-cut decal.

3. With the machine on level surface, position one blade front-to-rear (Fig. 69). Measure at A and from level surface to the cutting edge of the blade tips (Fig. 70).

4. The measurement should be 4 inch (101.6 mm).

Front

m–1078

Figure 67

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

Figure 68

m–2550

Changing the Side-to-Side Leveling

Changing the side–to–side leveling is done by adjusting tire pressure.

m–1078

Figure 69

MEASURE FROM

CUTTING EDGE TO

A LEVEL SURFACE

Figure 70

5. If it does not measure correctly, add air pressure in rear tires to raise height–of–cut

6. If it does not measure correctly, decrease air pressure in rear tires to lower height–of–cut.

7. Check carrier frame front–to–rear pitch.

m–2550

Replacing the Mower Belt

Changing the Side–to–Side Leveling with Tire Pressure

1. Change the tire pressure on both deck and traction unit. Do this to the corresponding side that needs adjustment.

2. Recheck the front-to-rear pitch and side to side leveling of the cutting unit.

Matching Height of Cut

1. Check the tire pressure on both deck and traction unit.

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn deck belt. Replace the deck belt if any of these conditions are evident.

1. Disengage the PTO and set the parking brake.

2. Stop the engine, remove the key, and wait for all

moving parts to stop before leaving the operating position.

3. Remove the knobs and rubber washers holding the carrier frame cover and remove the carrier frame cover.

4. Remove the knobs and rubber washers holding the belt cover to the cutting unit and remove the belt cover.

5. Remove the PTO drive belt. Refer to Replacing the PTO Drive Belt on page 48.

6. Disconnect the idler arm spring to relieve tension on the idler arm and idler pulley, then remove the worn mower belt (Fig. 71).

7. Install the new mower belt around the outward spindle pulley, the idler pulley, and in the lower groove of the double spindle pulley (Fig. 71).

8. Reconnect the idler arm spring (Fig. 71).

9. Install the PTO drive belt. Refer to Replacing the PTO

Drive Belt on page 48.

10. Reinstall the belt cover onto the cutting unit, then reinstall and tighten the knobs and rubber washers.

11. Install the carrier frame cover onto the cutting unit, then install and tighten the knobs and rubber washers.

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

3. Remove the knobs and rubber washers holding the carrier frame cover and remove the carrier frame cover.

4. Remove the knobs and rubber washers holding the belt covers to the top of the cutting unit and remove the belt covers.

5. Remove the heat shield from the the engine deck and carrier frame.

6. Remove the idler spring from idler arm. Remove the drive belt from the PTO clutch pulley, idler pulleys and the left spindle pulley (Fig. 72).

7. Install the new drive belt onto the PTO engagement pulley and the top groove of the center spindle pulley (Fig. 72).

8. Install belt onto idler pulleys and then install idler spring (Fig. 72).

m–7905

Figure 71

1. Mower belt

2. Idler arm spring

3. Outward pulley

4. PTO Drive Belt

5. Double Spindle Pulley

Replacing the PTO Drive Belt

Squealing when the belt is rotating, blades slipping when cutting grass, frayed belt edges, burn marks and cracks are signs of a worn drive belt. Replace the drive belt if any of these conditions are evident.

1. Disengage the PTO and set the parking brake.

9. Install the heat shield to the engine deck and carrier

frame.

10. Reinstall the belt covers onto the cutting unit, then reinstall and tighten the knobs and rubber washers.

11. Reinstall the carrier frame cover onto the cutting unit, then reinstall and tighten the knobs and rubber washers.

m–7905

Figure 72

1. PTO clutch pulley

2. Drive belt idler

3. Drive Belt

4. Double Spindle Pulley

Replacing the Caster Wheel Fork Bushings

The caster wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame mounting tubes. To check the bushings, move the caster forks back and forth and side-to-side. If a caster fork is loose, the bushings are worn and must be replaced.

1. Raise the cutting unit so the caster wheels are off the floor, then block up the front of the mower with jack stands.

2. Remove the locking pin and spacer(s) from the top of the caster wheel fork (Fig. 73).

3. Pull the caster wheel fork out of the mounting tube, leaving the spacer(s) on the bottom of the fork. Remember the location of the spacers on each fork to ensure correct installation, and to maintain a level deck.

6. Inspect the caster wheel fork for wear and replace if necessary (Fig. 73).

7. Slide the caster wheel fork through the bushings in the mounting tube. Replace the spacer(s) onto the fork and secure with the retaining ring (Fig 73).

Important The inside diameter of the bushings may

collapse slightly when installed. If the caster wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 1.126 inch (29 mm).

8. Grease the fitting on the carrier frame mounting tube using No. 2 general purpose lithium base or molybdenum base grease.

m–6373

Figure 74

1. Mounting Tube 2. Bushing

m–6372

Figure 73

1. Locking Pin

2. Spacers (locate as required)

4. Insert a pin punch into the mounting tube and carefully drive out the bushings (Fig. 74). Clean the inside of the mounting tube.

5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the mounting tube.

3. Carrier frame mounting tube

4. Caster wheel fork

Caster Wheel and Bearings Service

The caster wheels rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly caster wheel usually indicates a worn bearing.

1. Remove the locknut and wheel bolt holding the caster wheel to the caster fork (Fig. 75).

2. Remove one bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 75).

3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 75).

4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 75).

3. Install bolt and nut. Place the J hook end of spring around grass deflector (Fig. 76).

Important The grass deflector must be able to lower

down into position. Lift the deflector up to test that it lowers into the full down position.

2 4

m–5210

Figure 75

1. Locknut

2. Wheel Bolt

3. Bushing

4. Spanner Bushing

5. Roller Bearing

5. To assemble, place one bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Fig. 75).

6. Install the caster wheel into the caster fork and secure with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the caster forks (Fig. 75).

7. Grease the fitting on the caster wheel.

Replacing the Grass Deflector

m–7904

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

Figure 76

6. Grass Deflector

7. L end of spring, place

behind deck edge before installing bolt

8. J hook end of spring

Warning

An uncovered discharge opening could allow the lawn mower to throw objects in the operator’s or bystander’s direction and result in serious injury. Also, contact with the blade could occur.

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Remove the locknut, bolt, spring and spacer holding

the deflector to the pivot brackets (Fig. 76). Remove damaged or worn grass deflector.

2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge.

Note: Make sure the L end of spring is installed behind

deck edge before installing the bolt as shown in figure 76.

Wiring Diagram

PTO Switch (Off)

WIRE COLOR CODES

BLACK

BROWN

BLUE

GREEN

GREY

ORANGE

VIO

PINK

RED

TAN

VIOLET

WHITE

YELLOW

Park Brake Switch (On)

Operator Presence Switch (No Operator)

Neutral Switch (In Neutral)

HR MTR MOD

–+

MTR

BNY

354

BK BK

Clutch

K1 Interlock Relay

10A

KEY SWITCH

(OPEN = ON) (CLOSED = OFF)

GND

SPARK PLUG SPARK PLUG

IGNITION MODULES

REG

MAG

Hydraulic Diagram

Motor Right Side

Motor Left side

Pump Right Side

Filter

Expansion Tank

Pump Left side

Charge Pump Inlet

Case Drain

m–5225

Cleaning and Storage

g,,

1. Disengage the power take off (PTO) and turn the ignition key to Off to stop the engine. Remove the key.

2. Remove grass clippings, dirt, and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine’s cylinder head fins and blower housing.

Important You can wash the machine with mild

detergent and water. Do not pressure wash the machine. Avoid excessive use of water, especially near the control panel, engine, hydraulic pumps and motors.

3. Service the air cleaner; refer to Servicing the Air Cleaner, page 27.

4. Change the crankcase oil; refer to Servicing the Engine Oil, page 28.

5. Change the hydraulic filter; refer to Servicing the Hydraulic System on page 33.

6. Check the tire pressure; refer to Checking the Tire Pressure, page 31.

7. For storage over 30 days, prepare the traction unit as follows.

A. Add a petroleum based stabilizer/conditioner to

fuel in the tank. Follow mixing instructions from stabilizer manufacturer. Do not use an alcohol

based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline and used at all times.

B. Run the engine to distribute conditioned fuel

through the fuel system (5 minutes).

C. Stop the engine, allow it to cool and drain the fuel

tank; refer to Draining the Fuel Tank, page 32.

D. Restart the engine and run it until it stops.

E. Choke or prime the engine.

F. Start and run the engine until it will not start again.

Use the primer, if equipped on machine, several times to ensure no fuel remains in primer system.

G. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

8. Remove the spark plug(s) and check its condition; refer to Servicing the Spark Plug on page 29. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

9. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged or defective.

10. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer.

11. Store the machine in a clean, dry garage or storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

Troubleshooting

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Engine will not start, starts hard, or fails to keep running.

1. Fuel tank is empty. 1. Fill fuel tank with gasoline.

2. PTO is on (Pulled up). 2. Turn PTO off (Push in).

3. Speed control lever is in gear. 3. Move speed control lever to

4. Choke is not ON. 4. Move choke lever to ON.

5. Air cleaner is dirty. 5. Clean or replace air cleaner

6. Spark plug wire is loose or

7. Spark plug is pitted, fouled, or

8. Dirt in fuel filter. 8. Replace fuel filter.

9. Dirt, water, or stale fuel is in

disconnected.

gap is incorrect.

fuel system.

neutral.

element.

6. Install wire on spark plug.

7. Install new, correctly gapped spark plug.

9. Contact Authorized Service Dealer.

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Engine loses power.

Engine overheats.

Machine does not drive.

1. Engine load is excessive. 1. Reduce ground speed.

2. Air cleaner is dirty. 2. Clean air cleaner element.

3. Oil level in crankcase is low. 3. Add oil to crankcase.

4. Cooling fins and air passages under engine blower housing are plugged.

5. Spark plug is pitted, fouled, or gap is incorrect.

6. Vent hole in fuel cap is plugged.

7. Dirt in fuel filter. 7. Replace fuel filter.

8. Dirt, water, or stale fuel is in fuel system.

1. Engine load is excessive. 1. Reduce ground speed.

2. Oil level in crankcase is low. 2. Add oil to crankcase.

3. Cooling fins and air passages under engine blower housing are plugged.

1. Neutral lock is in neutral position.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plug.

6. Clean or replace the fuel cap.

8. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

1. Move neutral lock to forward position.

2. Hydrostatic fluid level low. 2. Fill hydrostatic fluid tank.

3. Traction belt is worn, loose or broken.

4. Traction belt is off pulley. 4. Install Belt.

Machine does not drive up hills or inclines.

Machine moves slowly in neutral. 1. Neutral is mis-adjusted.

Machine drive is too aggressive. 1. By-pass valve is adjusted too

Machine tracks left or right.

1. By-pass valve is adjusted too far open.

2. Neutral control spring is broken or missing.

far closed.

1. Tire pressure is not correct. 1. Adjust tire pressure.

2. Tracking knob not adjusted correctly.

3. Change Belt.

1. Adjust by-pass valve.

1. Adjust hydro linkages.

2. Replace neutral control spring.

1. Adjust by-pass valve.

2. Adjust tracking knob.

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Abnormal vibration.

Uneven cutting height.

1. Cutting blade(s) is/are bent or unbalanced.

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Engine mounting bolts are loose.

4. Loose engine pulley, idler pulley, or blade pulley.

5. Engine pulley is damaged. 5. Contact Authorized Service

6. Blade spindle bent. 6. Contact Authorized Service

1. Blade(s) not sharp. 1. Sharpen blade(s).

2. Cutting blade(s) is/are bent. 2. Install new cutting blade(s).

3. Mower is not level. 3. Level mower from side-to-side

4. Underside of mower is dirty. 4. Clean the underside of the

5. Tire pressure is incorrect. 5. Adjust tire pressure.

6. Blade spindle bent. 6. Contact Authorized Service

1. Install new cutting blade(s).

3. Tighten engine mounting bolts.

4. Tighten the appropriate pulley.

Dealer.

and front-to-rear.

mower.

Dealer.

Blades do not rotate.

1. PTO Drive belt is worn, loose or broken.

2. PTO Drive belt is off pulley. 2. Install drive belt and check

3. Deck belt is worn, loose or broken.

4. Deck belt is off pulley. 4. Install deck pulley and check

1. Install new drive belt.

adjusting shafts and belt guides for correct position.

3. Install new deck belt.

the idler pulley, idler arm and spring for correct position and function.

Landscape Contractor Equipment (LCE)

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro product if defective in materials or workmanship.

This warranty applies to:

• ProLine Mid-Size Walk Power Mowers and Accessories

• Z Master Mid-Mount ZRTs and Accessories

The following time periods apply from the date of purchase:

Components

• Engines* 2 years

• Hydraulic Systems 2 years

• Traction Unit Frame 2 years

• Carrier Frame 2 years

• Deck Shells 2 years

• Deck Spindles 3 years Parts, 2 years Labor

• Z500 Series Clutches 2 years

• Remaining Components 1 year

This warranty includes the cost of parts and labor, but you must pay transportation costs.

* Some engines used on Toro LCE products are warranted by the

engine manufacturer.

Warranty Period

Instructions for Obtaining Warranty Service

If you think that your Toro LCE product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to

arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. You may also call our Toro Customer Care Department toll free at 888-865–5676 (U.S. customers) or 888-865–5691 (Canada customers).

2. Bring the product and your proof of purchase (sales receipt) to

the Service Dealer.

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, call us toll free at the numbers above or write us at:

LCE Customer Care Department 8111 Lyndale Avenue South Bloomington, MN 55420-1196

You must maintain your Toro product by following the maintenance procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.

There is no other express warranty except for special emission system coverage on some products. This express warranty does not cover the following:

• Cost of regular maintenance service or parts, such as filters, fuel, lubricants, tune-up parts, blade sharpening, brake and clutch adjustments.

• Any product or part which has been altered or misused or required replacement or repair due to normal wear, accidents, or lack of proper maintenance.

• Repairs necessary due to improper fuel, contaminants in the fuel system, or failure to properly prepare the fuel system prior to any period of non-use over three months.

• Pickup and delivery charges.

• Operational misuse, neglect, or accidents.

• Repairs or attempted repairs by anyone other than an

Authorized Toro Service Dealer using Toro approved parts.

All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts.

Repair by an Authorized Toro Service Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

All implied warranties of merchantability (that the product is fit for ordinary use) and fitness for use (that the product is fit for a particular purpose) are limited to the duration of the express warranty.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Part No. 374-0037 Rev. E

Toro 30433 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual