Page 1
Form No. 3352–529
Mid-Size Mower
ProLine Hydro 15 hp with 48in Side Discharge
Mower
Model No. 30528—Serial No. 250000001 and Up
Operator’s Manual
Register your product at www.Toro.com
Original Instructions (EN)
Page 2
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 mower.
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 4. . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 9. . . . . . . . . . . . . . . .
Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Gasoline 12. . . . . . . . . . . . . . . . . . . .
Using Fuel Stabilizer/Conditioner 12. . . . . . . . . . . .
Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .
Checking the Engine Oil Level 12. . . . . . . . . . . . . .
Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Front Casters 14. . . . . . . . . . . . . . . . . .
Installing the Upper Handle 14. . . . . . . . . . . . . . . . .
Connecting the Throttle Cable 15. . . . . . . . . . . . . . .
Installing the Blade Control (PTO) Rod 15. . . . . . . .
Installing the Control Rods 15. . . . . . . . . . . . . . . . . .
Installing the Control Arm Rods 16. . . . . . . . . . . . .
W 2004 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
Installing the Speed Control Rod 16. . . . . . . . . . . . .
Installing the Fuel Tank 17. . . . . . . . . . . . . . . . . . . .
Setting up the Hydro Linkage 17. . . . . . . . . . . . . . .
Checking the Hydraulic Fluid 18. . . . . . . . . . . . . . .
Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 19. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Parking Brake 19. . . . . . . . . . . . . . . .
Starting and Stopping the Engine 20. . . . . . . . . . . . .
Operating the Neutral Locks 21. . . . . . . . . . . . . . . .
Operating the Mower Blade Control (PTO) 21. . . . .
The Safety Interlock System 22. . . . . . . . . . . . . . . .
Driving the Machine Forward or Backward 22. . . . .
Bringing the Machine to Neutral Position 23. . . . . .
Stopping the Machine 23. . . . . . . . . . . . . . . . . . . . . .
Pushing the Machine by Hand 23. . . . . . . . . . . . . . .
Transporting Machines 24. . . . . . . . . . . . . . . . . . . . .
Using the Side Discharge or Mulching Grass 24. . . .
Adjusting the Height-of-Cut 24. . . . . . . . . . . . . . . . .
Adjusting the Caster Position 25. . . . . . . . . . . . . . . .
Height-of-Cut Chart 26. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 27. . . . . . . . .
Servicing the Cutting Blades 28. . . . . . . . . . . . . . . .
Servicing the Air Cleaner 30. . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 31. . . . . . . . . . . . . . . . . . .
Servicing the Spark Plug 32. . . . . . . . . . . . . . . . . . .
Servicing the Brake 33. . . . . . . . . . . . . . . . . . . . . . .
Checking the Tire Pressure 34. . . . . . . . . . . . . . . . . .
Cleaning the Cooling System 34. . . . . . . . . . . . . . . .
Greasing and Lubricating the Machine 34. . . . . . . .
Cleaning the Cooling System 35. . . . . . . . . . . . . . . .
Draining the Fuel Tank 35. . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel Filter 35. . . . . . . . . . . . . . . . . . . .
Servicing the Hydraulic System 36. . . . . . . . . . . . . .
Performing the Hydro Linkage Adjustments 37. . . .
Adjusting the Speed Control Linkage 37. . . . . . . . .
Adjusting the Neutral Control Linkages 38. . . . . . . .
Adjusting the Hydro Control Linkages 39. . . . . . . .
Adjusting the Control Rod 41. . . . . . . . . . . . . . . . . .
Tracking the Adjustment 41. . . . . . . . . . . . . . . . . . .
Adjusting the Spring Anchor Links 41. . . . . . . . . . .
Checking the Belts 42. . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mower Belt 42. . . . . . . . . . . . . . . . . .
Adjusting the Mower Belt Tension 43. . . . . . . . . . . .
Adjusting the Blade Brake 43. . . . . . . . . . . . . . . . . .
Replacing the Grass Deflector 44. . . . . . . . . . . . . . .
Wiring Diagram 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Diagram 45. . . . . . . . . . . . . . . . . . . . . . . .
Contact us at www.Toro.com
All Rights Reserved
2
Printed in the USA
Page
Page 3
Cleaning and Storage 46. . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .
Page
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
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.
1
Figure 1
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
Safety
This machine meets or exceeds the B71.4–2004
specifications of the American National Standards
Institute in effect at the time of production.
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.
Safe Operating Practices
The following instructions are from ANSI standard
B71.4—2004.
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.
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
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.
• 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.
3
Page 4
• 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
• 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.
• 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 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.
• 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.
• 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.
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.
• 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.
• 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.
Toro Mower Safety
The following list contains safety information specific to
Toro products and other safety information you must know.
4
Page 5
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.
• Use only Toro-approved attachments. Warranty may be
voided if used with unapproved attachments.
Slope Operation
• 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.
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.
DO
• 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.
5
Page 6
6
Page 7
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.)
7
Page 8
8
Page 9
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.
1-403005
66-1340
93-1122
1-523552
95-2814
95-5537
1. Read the Operator’s Manual for instructions on operating the
cutting blade
2. Push forward to engage
3. Pull back to disengage
9
Page 10
98-0776
98-5130
1. Warning—read the Operator’s Manual for instructions on
torquing the blade bolt/nut to 75-80 ft.-lb.(102-106 N⋅m).
98-5954
99-3943
1. Engine
105-4109
105-4110
10
106-0699
106-2743
Page 11
1. Forward
2. Neutral
3. Reverse
4. Warning—wear hearing
protection.
106-0829
5. Fast
6. Continuous variable setting
7. Slow
8. Neutral
11
Page 12
Gasoline and Oil
Warning
Recommended Gasoline
Use unleaded regular gasoline suitable for automotive use
(85 pump octane minimum). Use leaded regular gasoline 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 in. (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
and 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.
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 Fuel
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, drain the fuel tank.)
• 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. Disengage the power take off (PTO) and turn the engine
off.
2. Wait for all moving parts to stop before leaving the
operating position and then set the parking brake.
3. Clean around the fuel tank cap and remove the cap. Add
unleaded regular gasoline to the fuel tank until the level
is 1/4 to 1/2 inch (6 mm to 13 mm) below the bottom of
the filler neck. This space in the tank allows gasoline to
expand. Do not fill the fuel tank completely full.
4. Install the fuel tank cap securely. Wipe up any spilled
gasoline.
Checking the 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 31.
12
Page 13
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.
DESCRIPTION QTY. USE
Caster assemblies
Bolt, 3/8 x 3/4 inch
Flange nut, 3/8 inch
Upper handle
Flanged bolt, 3/8 x 1 inch
Flanged nut, 3/8 inch
Spring washer
Wire tie
Hairpin cotter 1 Installing the blade control rod
Clevis pin
Hairpin cotter
Washer
Hairpin cotter
Clevis pin
Hairpin cotter
Fuel tank
Bolt, 5/16 x 3/4 inch
2
8
8
1
4
4
4
4
2
2
2
2
1
2
1
2
Installing the front casters
Installing the upper handle and wire harness
Installing the control rods
Installing the drive linkage
Installing the speed control rod
Lock washer, 5/16 inch
Locknut
Washer, 5/16 inch
Stud
Spring
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Video
Registration card 1 Fill out and return to Toro
2
2
4
2
2
1
1
1
1
13
Installing the fuel tank
Review before operating machine
Page 14
Installing the Front Casters
1. Align the casters with the holes on the top and front of
the mower, and insert 8 bolts (3/8 x 3/4 inch) through
the mower. Secure the caster with 8 flange nuts
(3/8 inch) below the mower (Fig. 2).
5
2
1
4
1
3
2
m–3777
Figure 2
1. Front caster
2. Bolt
3. Flange nut
Note: Tighten the lower bolts first to pull the caster
against the front, then tighten the top bolts.
2. Torque the bolts to 30–35 ft.-lb. (40–47 NSm).
Installing the Upper Handle
1. Align the holes in upper handle with the mounting holes
in the rear frame and bracket (Fig. 3).
m–5969
Figure 3
1. Upper handle
2. Rear frame bracket
3. Flange bolt (26 mm)
4. Spring washer
5. Flange nut
Important Install the flange bolts with the bolt head on
the outside of the upper handle. Refer to figure 3.
2. Secure each leg of the upper handle to the rear frame
and bracket with two flange bolts (3/8 x 1 inch
(26 mm), spring washers and flange nuts (Fig. 3).
Tighten until spring washers are compressed.
3. Route the wire harness along the inside of the left
handle and under the control panel (Fig. 17).
4. Connect the right-angled insulated terminals to the
switch (Fig. 4).
1
2
3
Figure 4
1. Switch 2. Right-angled insulated
terminals
5. Use the wire ties to secure the wire harness to the inside
of the left handle, away from the blade control (PTO)
rod (Fig. 17). Secure at bottom and top of handle.
14
m–6490
Page 15
Connecting the Throttle Cable
1. Place throttle control lever in the fast position (Fig. 5).
2. Hook wire Z–bend into hole of speed control lever
(Fig. 5).
3. Loosen cable clamp screw allowing cable installation,
but do not tighten (Fig. 5).
4. Move control cable casing and wire until hole in speed
control lever is aligned with hole in base plate. Insert a
1/4 in. (6 mm) diameter pin or bolt into aligned holes to
hold adjustment.
5. Pull throttle cable slightly to remove any slack and
tighten cable clamp screw to lock adjustment in place.
6. Remove alignment pin and check control operation.
5
3
1
1
3
2
Figure 6
1. Blade control (PTO) rod
2. Bell crank
3. Hairpin cotter
2. Secure the blade control (PTO) rod to the bell crank
with a hairpin cotter (Fig. 6).
Installing the Control Rods
m–5997
4
2
Figure 5
1. Wire Z-bend
2. Speed control lever
3. Base plate
4. Alignment holes 1/4 in.
(6 mm)
5. Cable clamp
Installing the Blade Control
(PTO) Rod
1. From outer side of bell crank, insert end of blade
control (PTO) rod thru hole (Fig. 6).
m–2596
1. Install the control rod to the drive lever and neutral lock
with a clevis pin and washer (Fig. 7). Washer to be
positioned between drive lever and neutral lock.
2. Install a hairpin cotter between drive lever and washer
and into clevis pin (Fig. 7).
Note: Make sure the clevis pin is inserted into the neutral
lock.
3. Repeat this procedure for the opposite side.
15
Page 16
1
6
2
Installing the Control Arm
Rods
1. Insert control arm swivel thru hole in speed control
crank and secure with hairpin cotter (Fig. 9).
3
4
5
1
7
m–5998
Figure 7
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
4. Thread rod fittings equal distance onto each control rod.
For a starting point, thread rod fittings onto control rod
approximately 2–1/2 inch (64 mm) from the bottom
(Fig. 8).
5. Install rod fittings to idler brackets with clevis pins and
e–ring (Fig. 8).
2
1
4
3
3
2
m–5994
Figure 9
1. Control arm
2. Swivel
3. Speed control crank
2. Repeat this procedure for the opposite side.
Installing the Speed Control
Rod
1. Move the speed control lever fully forward (Fig. 10).
1
1. Control rod
2. Idler bracket
3. Rod fitting
5
Figure 8
m–5400
4. E–ring
5. 2–1/2 inch (64 mm) from
bottom
Figure 10
1. Speed control lever
2. Install speed control rod to right side of speed control
lever (under control panel) with a hair pin cotter
(Fig. 11).
16
Page 17
2
1
3
Figure 11
1. Speed control rod
2. Speed control lever
3. Hair pin cotter
3. Install yoke end of speed control rod to the speed
control crank with a clevis pin and hairpin cotter
(Fig. 12).
m–5996
Installing the Fuel Tank
1. Apply retaining adhesive, such as Loctite RC 609 or
680, to the threads of the 2 threaded studs (5/16 x
7/8 inch) supplied in loose parts. Install studs into the
two left holes in underside of fuel tank
2. Align the fuel tank to the top of the rear frame, and
secure the right side of the fuel tank with 2 bolts (5/16 x
3/4 inch), 2 lock washers (5/16 in.), and 2 washers
(5/16 in.) (Fig. 13).
3
2
1
1. Bolt, 5/8 x 7/8 inch (2)
2. Lock washer, 5/16 inch
(2)
3. Washer, 5/16 inch (2)
Figure 13
4. Stud (2)
5. Spring (2)
6. Locknut (2)
m-6488
4
3
5
6
3
2
4
1. Speed control rod
2. Yoke
3. Speed control crank
Figure 12
4. Hair pin cotter
5. Clevis pin
1
3. Secure the fuel tank studs to the frame with 2 washers
(5/16 in.), 2 springs, and 2 locknuts (5/16 in.) (Fig. 13).
Note: Tighten the left side of the fuel tank until it is
5
completely tight, then unscrew the locknut one full turn.
This allows the spring to work.
4. Push the fuel line onto the fuel tank fitting, and secure
the fuel line with a hose clamp (Fig. 14).
2
3
1
m–6442
Figure 14
1. Fuel line
2. Hose clamp
3. Fuel fitting
Setting up the Hydro Linkage
Perform the following adjustments when the machine is
first set up and when any adjustment is needed. Do them in
the order that they are listed here.
17
Page 18
Adjusting the Speed Control Linkage
Refer to Adjusting the Speed Control Linkages on page 37.
Adjusting the Neutral Control Linkages
1
2
Refer to Adjusting the Neutral Control Linkages on
page 38.
Adjusting the Hydro Control Linkages
Refer to Adjusting the Hydro Control Linkages on page 39.
Adjusting the Control Rods
Refer to Adjusting the Control Rods on page 41.
Adjusting the Tracking
Refer to Adjusting the Tracking on page 41.
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 25 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: 77 oz. (2.3 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.
2. Disengage the power take off (PTO) and turn the engine
off.
3. Wait for all moving parts to stop before leaving the
operating position and then set the parking brake.
4. Clean area around cap and filler neck of hydraulic tank
(Fig. 15).
4
m–5615
Figure 15
1. Cap
2. Baffle
5. Remove cap from filler neck. Look inside to check if
there is fluid in the reservoir. (Fig. 15).
6. If there is no fluid, add fluid to the reservoir until it
reaches the cold level of the baffle.
7. 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 20.
8. 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
of the baffle, when the fluid is warm (Fig. 15).
9. Install cap on filler neck.
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.
3
18
Page 19
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
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.
1
2
Speed control lever – This machine has a variable speed
control with a neutral position. This controls how fast the
machine will travel.
Drive levers – Release drive levers to engage forward
traction operation and squeeze to reverse. Squeeze right
side of drive lever to turn right and left side to turn left.
Neutral lock – Squeeze drive levers back and move locks
to the rear for neutral lock. Squeeze drive levers back and
move locks to the front for parking brake lock.
Recoil Starter – Pull recoil starter handle to start engine.
Fuel Shut–off Valve – (Inline) Close fuel shut–off valve
when transporting or storing mower.
Parking Brake Lever – The parking brake lever is on the
right side. Pull up on the brake lever to set the parking
brake.
65
1
2
4
Figure 16
1. Caution 2. Wear hearing protection
Controls
Become familiar with all the controls (Fig. 17) before you
start the engine and operate the machine.
Throttle control – The throttle control has Choke, Fast,
Slow and Stop positions.
Operator Presence Control (OPC) levers – When you
squeeze the OPC levers against the handles, the OPC
system senses that the operator is in the normal operating
position. When you release the OPC levers, the OPC
system senses that the operator has left the normal
operating position, and the system will stop the engine if
either the speed control lever is not in the Neutral position
or the blade control (PTO) lever is engaged.
Blade control knob (PTO) – Push/pull knob is used in
conjunction with OPC levers to drive mower blades.
3
m–6487
Figure 17
1. Throttle control
2. Operator Presence
Control levers (OPC)
3. Blade control knob (PTO)
4. Drive lever
5. Neutral lock
6. Ignition switch
7. Speed control lever
Operating the Parking Brake
Always set the parking brake when you stop the machine or
leave it unattended. Before each use, check the parking
brake for proper operation.
If the parking brake does not hold securely, adjust it. Refer
to Servicing the Brake on page 33.
19
Page 20
Caution
Children or bystanders may be injured if they
move or attempt to operate the machine while it is
unattended.
Always remove set the parking brake when leaving
the machine unattended, even if just for a few
minutes.
Setting the Parking Brake
Pull the parking brake lever rearward (Fig. 21).
To use cold start kit:
• Grasp split ring (Fig. 19) on right side of machine,
pull ring and chain straight out from side of machine
and hook ring over control shield bolt.
1
1
m-6102
Figure 18
1. Parking brake lever (in the released position)
Releasing the Parking Brake
Push the parking brake lever forward.
Starting and Stopping the
Engine
Starting
1. Connect the wires to the spark plugs.
2. Open the fuel valve.
Note: A cold weather staring kit has been incorporated to
assist engine starting in cold weather or when the unit has
not been run for a period of time.
2
Figure 19
1. Split ring 2. Control shield bolt
• After engine is started, pull chain straight out from
side of machine until ring can be removed from
shield bolt. Slowly release tension on chain.
3. Disengage the blade control (PTO) and move the speed
control lever to neutral.
4. Move the drive levers to neutral and set the neutral
locks.
5. Set the parking brake.
6. Move the speed control lever to neutral.
7. Move the throttle control to the choke position before
starting a cold engine.
8. Grasp the recoil starter handle firmly and pull it out
until positive engagement results; then pull the handle
vigorously to start the engine. Allow the rope to recoil
slowly.
m–6473
Stopping
1. Move the throttle lever to slow (Fig. 20).
2. Move drive levers to neutral and set neutral locks.
3. Disengage the blade control (PTO) and move the speed
control lever to neutral.
4. Let engine idle for 30 to 60 seconds before turning the
engine off.
5. To stop the engine, pull the throttle all the way back to
stop (Fig. 20).
20
Page 21
1
Releasing the Neutral Lock
1. Squeeze the drive levers back.
2. Place thumbs on the upper part of of locks and move
them forward until in forward slot (Fig. 21).
2
1
6
m–6487
Figure 20
1. Throttle lever
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 the Neutral Locks
Always set the neutral lock when you stop the machine.
Chock or block wheels if it is left unattended.
Setting the Neutral Lock
1. Squeeze the drive levers back.
2. Place thumbs on the upper part of of locks and move
them back (Fig. 21).
5
3
1. Handle
2. Neutral lock
3. Neutral position
4
Figure 21
4. Drive lever
5. Full speed forward
6. Reverse position
m–5388
Operating the Mower Blade
Control (PTO)
The blade control knob (PTO) is used in conjunction with
the Operator Presence Control (OPC) levers to engage and
disengage the mower blades.
Engaging the Mower Blades (PTO)
1. To engage blades, squeeze the Operator Presence
Control (OPC) levers against handle grips (Fig. 22).
2. Pull blade knob (PTO) up. Hold the OPC levers against
handle grip.
21
Page 22
2
The safety interlock system is designed to kill the engine
when:
1
4
3
Figure 22
1. Handle
2. Operator Presence
Control levers (OPC)
3. Blade control knob (PTO)
4. Drive Lever
Disengaging the Mower Blades (PTO)
The mower blades can be disengaged by one of the
following steps.
1. Push the blade control knob (PTO) down to off
(Fig. 22).
2. Release Operator Presence Control (OPC) levers to
disengage blades (Fig. 22). This will also kill the
engine.
m–6487
• The Operator Presence Control (OPC) levers are
released.
• The speed control lever is shifted out of neutral without
holding OPC levers.
• The blade control knob (PTO) is pulled up 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 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 20.
2. Without holding the Operator Presence Control (OPC)
levers, pull the blade control knob (PTO) up. The
engine should kill.
3. Push the blade control knob down to off.
4. With engine running, hold down the OPC levers. Pull
the blade control knob (PTO) up. The clutch should
engage and the mower blades begin rotating.
5. Release the OPC levers. The engine should kill.
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 knob (PTO) is pushed off.
• The speed control lever is in neutral.
6. With the engine running, move the speed control lever
forward. Release the OPC levers. The engine should
kill.
7. If all the above conditions are not met have an
Authorized Service Dealer repair the safety system
immediately.
Driving the Machine 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. To go forward, move the speed control lever to desired
speed.
2. Release the neutral lock. Refer to Releasing the Neutral
Lock on page 21.
3. Slowly release the drive levers to move forward
(Fig. 23).
To go straight, release drive levers equally (Fig. 23).
22
Page 23
To turn, squeeze the drive lever on the side and direction
you want to turn (Fig. 23).
4. Stop the engine by pulling the throttle all the way back
to stop (Fig. 20).
2
1
m–6487
Figure 23
1. Drive lever 2. Speed control lever
Backward
1. To go backward, move the speed control lever to
desired speed.
2. Release the neutral lock. Refer to Releasing the Neutral
Locks on page 21.
3. Slowly squeeze the drive levers back together to move
rearward (Fig. 23).
Bringing the Machine to
Neutral Position
5. Wait for all moving parts to stop before leaving the
operating position and then set the parking brake.
Caution
Children or bystanders may be injured if they
move or attempt to operate the machine while it is
unattended.
Always remove set the parking brake when leaving
the machine unattended, even if just for a few
minutes.
Pushing the Machine by Hand
The by–pass valves allow the machine to be pushed by
hand without the engine running.
Important Always push the machine by hand. Never
tow the machine because hydraulic damage may occur.
To Push the Machine
1. Disengage the power take off (PTO) and turn the engine
off.
2. Rotate the by-pass valves open 1/2 turn. This allows
hydraulic fluid to by-pass the pumps and the wheels to
turn (Fig. 24).
3. When closing by-pass valves, do not overtighten.
Always set the neutral lock and parking brake when you
stop the machine.
1. Squeeze the drive levers back.
2. Set the neutral locks. Refer to Operating Neutral Locks
on page 21.
3. Move speed control lever to neutral position.
Stopping the Machine
1. To stop the machine, squeeze the drive levers and
engage the neutral locks.
2. Move neutral locks into the neutral position. Refer to
Operating Neutral Locks on page 21.
3. Move speed control lever into neutral.
1
m–5955
Figure 24
1. By-pass valve
m-5955
Important Do not start or operate the machine with the
by–pass valves open. Damage to system may occur.
23
Page 24
Transporting Machines
Adjusting the Blade Height
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.
Using the Side Discharge or
Mulching 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. Stop the engine and pull
the wire off the spark plug(s).
Adjusting the Height-of-Cut
This machine has a 1 to 4-1/4 inch (26 to 108 mm) range
for height-of-cut. This can be achieved by adjusting blade
spacers, rear axle height and front caster spacers. Use the
Height-of-Cut chart on page 26 to select the combination
required
Adjust the Blades by using the 4 spacers (1/4 inch) spacers
on the blade spindle bolts. This allows a range, in 1/4 inch
(6 mm) increments, of cutting height in any axle position.
Use the same number of blade spacers on all blades to
achieve a level cut (2 above and 2 below, 1 above and 3
below, etc.).
1. Disengage the power take off (PTO) and turn the engine
off.
2. Wait for all moving parts to stop before leaving the
operating position. Set the parking brake.
3. Hold the blade bolt and remove the nut. Slide the bolt
down through the spindle, and change the spacers as
needed (Fig. 25).
4
1
2
1. Blade
2. Blade bolt
3. Cone washer
4. Insert a bolt, add extra spacers, and secure them with a
thin washer and a nut (Fig. 25).
5. Torque the blade bolt to 75–80 ft.-lb. (101–108 NSm).
3
m–3779
Figure 25
4. Spacer
5. Thin washer
6. Nut
Adjusting the Axle Height
You can obtain the desired height-of-cut range by adjusting
the rear axle and placing the caster spacers above or below
the caster arm (refer to the Height-of-cut Chart, page 26).
1. Disengage the power take off (PTO) and turn the engine
off.
2. Wait for all moving parts to stop before leaving the
operating position and then set the parking brake.
3. Place a jack under the rear center of the engine frame.
Raise the back end of the engine frame up enough to
remove the drive wheels.
6
5
4
4. Remove the drive wheels.
24
Page 25
5. Loosen, but do not remove, the 2 axle pivot bolts
(Fig. 26).
6. Remove the 2 axle adjustment bolts (Fig. 26).
1
E
D
C
B
A
Figure 26
1. Axle pivot bolt
7. Raise or lower the mounting bracket, so that you can
install the 2 axle adjustment bolts in the desired hole
location (Fig. 26). A tapered punch can be used to help
align the holes.
8. Tighten all 4 bolts.
9. Install drive wheels and lower the mower.
Adjusting the Caster Position
1. Using the Height-of-Cut Chart (on page 26), adjust the
caster spacers to match with the axle hole selected
(Fig. 27).
2
1. Clevis pin
2. Spacer, 3/16 inch (5 mm)
Figure 27
3. Spacer, 1/2 inch (13 mm)
1
3
m–3791
2. Remove the clevis pin, slide the caster from the support,
and change the spacers (Fig. 27).
3. Install the caster in the support and insert the clevis pin
(Fig. 27).
25
Page 26
Height-of-Cut Chart
No. of Spacers Below
Caster
Number of 1/4 inch Blade Spacers Below Spindle
Axle
Position
A 0 0
A 0 1
A 1 0
B 0 1
B 1 0
B 1 1
B 2 0
C 1 1
C 2 0
1/2 inch
(13mm)
3/16 inch
(5 mm)
4 3210
1 inch
(26 mm)
1–1/8 inch
(29 mm)
1–3/8 inch
(35 mm)
1–3/8 inch
(35 mm)
1–5/8 inch
(41 mm)
1–3/4 inch
(45 mm)
2 inch
(45 mm)
1–7/8 inch
(48 mm)
2–1/8 inch
(55 mm)
1–1/4 inch
(32 mm)
1–3/8 inch
(35 mm)
1–5/8 inch
(41 mm)
1–5/8 inch
(41 mm)
1–7/8 inch
(48 mm)
2 inch
(52 mm)
2–1/4 inch
(58 mm)
2–1/8 inch
(55 mm)
2–3/8 inch
(61 mm)
1–1/2 inch
(38 mm)
1–5/8 inch
(41 mm)
1–7/8 inch
(48 mm)
1–7/8 inch
(48 mm)
2–1/8 inch
(55 mm)
2–1/4 inch
(58 mm)
2–1/2 inch
(64 mm)
2–3/8 inch
(61 mm)
2–5/8 inch
(67 mm)
1–3/4 inch
(45 mm)
1–7/8 inch
(48 mm)
2–1/8 inch
(55 mm)
2–1/8 inch
(55 mm)
2–3/8 inch
(61 mm)
2–1/2 inch
(64 mm)
2–3/4 inch
(70 mm)
2–5/8 inch
(67 mm)
2–7/8 inch
(73 mm)
2 inch
(45 mm)
2–1/8 inch
(55 mm)
2–3/8 inch
(55 mm)
2–3/8 inch
(61 mm)
2–5/8 inch
(67 mm)
2–3/4 inch
(70 mm)
3 inch
(76 mm)
2–7/8 inch
(73 mm)
3–1/8 inch
(79 mm)
C 2 1
C 3 0
D 2 1
D 3 0
D 3 1
D 4 0
E 3 1
E 4 0
E 4 1
2–1/4 inch
(58 mm)
2–1/2 inch
(64 mm)
2–3/8 inch
(61 mm)
2–1/2 inch
(64 mm)
2–3/4 inch
(70 mm)
3 inch
(76 mm)
2–7/8 inch
(73 mm)
3–1/8 inch
(79 mm)
3–1/4 inch
(82 mm)
2–1/2 inch
(64 mm)
2–3/4 inch
(70 mm)
2–5/8 inch
(67 mm)
2–3/4 inch
(70 mm)
3 inch
(76 mm)
3–1/4 inch
(82 mm)
3–1/8 inch
(79 mm)
3–3/8 inch
(86 mm)
3–1/2 inch
(89 mm)
2–3/4 inch
(70 mm)
3 inch
(76 mm)
2–7/8 inch
(73 mm)
3 inch
(76 mm)
3–1/4 inch
(82 mm)
3–1/2 inch
(89 mm)
3–3/8 inch
(86 mm)
3–5/8 inch
(92 mm)
3–3/4 inch
(96 mm)
3 inch
(76 mm)
3–1/4 inch
(82 mm)
3–1/8 inch
(79 mm)
3–1/4 inch
(82 mm)
3–1/2 inch
(89 mm)
3–3/4 inch
(96 mm)
3–5/8 inch
(92 mm)
3–7/8 inch
(99 mm)
4 inch
(102 mm)
3–1/4 inch
(82 mm)
3–1/2 inch
(89 mm)
3–3/8 inch
(86 mm)
3–1/2 inch
(89 mm)
3–3/4 inch
(96 mm)
4 inch
(102 mm)
3–7/8 inch
(99 mm)
4–1/8 inch
(105 mm)
4–1/4 inch
(108 mm)
26
Page 27
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 5 hours • Engine Oil—change
After first 8 Hours • Hydraulic Oil—check
8 Hours
25 Hours • Foam Air Cleaner—service
40 Hours
50 Hours • Belts—check for wear/cracks
100 Hours
Maintenance Procedure
• Engine Oil—check level
• Safety System—check
• Engine—clean outside
• Mower Housing—clean
• Cutting Blades—check
• Mower Housing—clean
• Caster Wheels—grease
• Caster Spindles—grease
• Mower Deck Idler Pivot—grease
• Pump Drive Idler Pivot—grease
• Pump Control—grease
• Tires—check pressure
• Hydraulic Oil—check
• Engine Oil—change
• Engine—clean outside
• Paper Air Cleaner—replace
• Hydraulic lines—check
• PTO Engagement Bellcrank—grease
1
1
1
After first 200 Hours • Hydraulic oil filter—change
• Fuel Filter—replace
200 Hours
At storage or 400 Hours
1
More often in dusty, dirty conditions.
Important Refer to your engine operator’s manual for additional maintenance procedures.
• Spark Plug(s)—check
• Oil Filter—change (200 hours or every other oil change)
• Hydraulic oil filter—change
• Chipped Surfaces—paint
• Perform all maintenance procedures listed above before storage
27
Page 28
Someone could accidently start the engine and seriously injure you or other bystanders.
Disconnect the wires from the spark plugs before you do any maintenance. Set the wire aside so
that it does not accidentally contact the spark plug.
Servicing the Cutting Blades
To ensure a superior quality of cut, keep the blades sharp.
For convenient sharpening and replacement, keep extra
blades on hand.
Caution
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 blades periodically for wear or
damage.
• Replace a worn or damaged blade.
Before Inspecting or Servicing the Blades
1. Park the machine on a level surface and disengage the
blade control (PTO).
2. Disengage the power take off (PTO) and turn the engine
off.
3. Wait for all moving parts to stop before leaving the
operating position. Set the parking brake.
Inspecting the Blades
2
1
3
m–151
Figure 28
1. Cutting edge
2. Curved area
3. Wear/slot forming
2. Inspect the blades, especially the curved area (Fig. 28).
If you notice any damage, wear, or a slot forming in this
area (item 3 in Fig. 28), immediately install a new
blade.
Checking for Bent Blades
1. Rotate the blades until the ends face forward and
backward (Fig. 29).
Front
1. Inspect the cutting edges (Fig 28). If the edges are not
sharp or have nicks, remove and sharpen the blades.
Refer to Sharpening the Blades, page 29.
C
C
D
D
Figure 29
2. Measure from a level surface to the cutting edge of the
blades (Fig. 30). Note this dimension.
28
C
D
m–1078
Page 29
6
MEASURE FROM CUTTING
EDGE TO A LEVEL SURFACE
m–2539
Figure 30
3. Rotate the opposite ends of the blades forward.
4. Measure from a level surface to the cutting edge of the
blades at the same position as in step 1 above. The
difference between the dimensions obtained in steps 1
and 2 must not exceed 1/8 inch (3 mm).
Note: If this dimension exceeds 1/8 inch (3 mm), the
blade is bent and must be replaced. Refer to Removing
the Blades, page 29 and Installing the Blades, page 30.
Warning
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.
4
1
3
2
m–3779
Figure 31
1. Blade
2. Blade bolt
3. Cone washer
4. Spacer
5. Thin washer
6. Nut
Sharpening the Blades
1. Use a file to sharpen the cutting edge at both ends of the
blade (Fig. 32). Maintain the original angle. The blade
retains its balance if the same amount of material is
removed from both cutting edges.
2
1
5
4
Removing the Blades
Replace the blades if you hit a solid object or if a blade is
out of balance or 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 bolt with a wrench.
2. Remove the nut, blade bolt, cone washer, blade,
spacers, and thin washer from the spindle (Fig. 31).
m–1854
Figure 32
1. Sharpen at original angle 2. Sail
2. Check the balance of the blade by putting it on a blade
balancer (Fig. 33). 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. 32). Repeat this step until the blade
is balanced.
2
1
m–1855
Figure 33
1. Blade 2. Balancer
29
Page 30
Installing the Blades
1. Place the blade onto the bolt and over the cone washer.
Select the proper number of spacers for the height-ofcut and slide the bolt into the spindle (Fig. 31).
Important The curved part of the blade must point
upward toward the inside of the mower to ensure proper
cutting.
2. Install the remaining spacers and secure them with a
thin washer and a nut (Fig. 31).
3. Torque the blade bolt to 75–80 ft.-lb. (101–108 NSm).
1
2
3
4
5
6
m–2595
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.
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. 34).
3. Remove the air cleaner assembly (Fig. 34).
4. Carefully slide the foam element off the paper element
(Fig. 34).
Figure 34
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. 35).
Squeeze the element to distribute the oil.
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.
2
1
Figure 35
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. 36).
30
m–5193
Page 31
2. Replace the paper element if it is damaged or
excessively dirty.
USE THESE SAE VISCOSITY OILS
10W–30
1
2
m–5192
Figure 36
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. 34).
2. Place the air cleaner assembly onto the air cleaner base
(Fig. 34).
3. Install the air cleaner cover and secure with cover nuts
(Fig. 34).
5W–20, 5W–30
–20 0 20
°
F
–30°–20 –10
C
40 60
32
01020
80 100
30 40
Checking the Engine Oil Level
1. Park the machine on a level surface.
2. Disengage the PTO and set the parking brake.
3. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
4. Clean around the oil dipstick (Fig. 37) so dirt cannot
fall into the filler hole and damage the engine.
5. Unscrew the oil dipstick and wipe the metal end clean
(Fig. 37).
6. Slide the oil dipstick fully into the filler tube, do not
thread onto tube (Fig. 37). 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.
Servicing the Engine Oil
Service Interval/Specification
Change oil:
• After the first 5 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 ounce (1.9 l)
Viscosity: See table below
Important Do not overfill the crankcase with oil
because the engine may be damaged.
1
3
1. Oil dipstick
2. Metal end
2
Figure 37
3. Filler tube
Changing the Engine Oil
1. Start the engine and let it run five minutes. This warms
the oil so it drains better.
31
Page 32
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 PTO and set the parking brake.
2. Remove the old filter and wipe the filter adapter
(Fig. 39) gasket surface.
3. Apply a thin coat of new oil to the rubber gasket on the
replacement filter (Fig. 39).
4. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
5. Slide the drain hose over the oil drain valve.
6. Place a pan below the drain hose. Rotate oil drain valve
to allow oil to drain (Fig. 38).
7. When oil has drained completely, close the drain valve.
8. Remove the drain hose (Fig. 38).
Note: Dispose of the used oil at a recycling center.
2
1
m–6438
Figure 38
1. Oil drain valve 2. Oil drain tube
1
3
2
m–1256
Figure 39
1. Oil filter
2. Gasket
3. Adapter
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. 39).
5. Fill the crankcase with the proper type of new oil; refer
to Changing the Engine Oil, page 31.
9. Change the oil filter, if necessary (Fig. 39).
10. Clean around the oil dipstick and unscrew the cap
(Fig. 37).
11. Slowly pour approximately 80% of the specified oil into
the filler tube (Fig. 37). Refer to Servicing the Engine
Oil, page 31.
12. Check the oil level; refer to Checking the Oil Level,
page 31.
13. Slowly add additional oil to bring it to the full mark.
Changing the Engine Oil Filter
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
Engine Oil, page 31.
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.
Type: Championr RC12YC or Championr Premium Gold
2071 (or equivalent)
Air Gap: 0.040 inch (1.02 mm)
Removing the Spark Plug(s)
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Pull the wire(s) off the spark plug(s) (Fig. 40). Now
clean around the spark plug(s) to prevent dirt from
falling into the engine and potentially causing damage.
4. Remove the spark plug(s) and metal washer.
32
Page 33
2
Servicing the Brake
Service Interval/Specification
Before each use, check the parking 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, adjust it.
1
Figure 40
1. Spark plug wire 2. Spark plug
m–4757
Checking the Spark Plug
1. Look at the center of the spark plug(s) (Fig. 41). 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. 41). Bend the side electrode if the gap is not
correct (Fig. 41).
2
1
3
0.040 inch
(1.02 mm)
Checking the Parking Brake
1. Move the machine onto a level surface.
2. Disengage the power take off (PTO) and stop the
engine.
3. Set the parking brake.
Note: Setting the parking brake should take a reasonable
amount of force. If it engages too hard or too easily,
adjustment is required. Refer to Adjusting the Parking
Brake on page 33.
Adjusting the Parking Brake
The parking brake lever is on the right side of the machine
(Fig. 18). If the parking brake does not hold securely, adjust
it.
1. Check the parking brake before you adjust it; refer to
Checking the Parking Brake on page 33.
2. Release the parking brake; refer to Releasing the
Parking Brake, page 20.
3. Remove the hair pin cotter and the clevis pin from the
lower brake lever (Fig. 42).
4. Rotate the brake linkage yoke in to tighten the parking
brake; rotate the brake linkage yoke out out to loosen
the parking brake (Fig. 42).
Figure 41
1. Center electrode insulator
2. Side electrode
3. Air gap (not to scale)
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. 40).
Note: There should be an approximately 1/4 in. clearance
between the tire and the flat bar when the parking brake in
the released position (Fig. 42).
5. Secure the brake linkage yoke to the lower brake lever
with the hair pin cotter and the clevis pin (Fig. 42).
6. Check the brake operation again; refer to Checking the
Parking Brake on page 33.
33
Page 34
This will help insure adequate cooling and correct engine
speed and will reduce the possibility of overheating and
mechanical damage to the engine.
1
2
Figure 42
1. Brake linkage yoke
2. Flat bar (Parking brake
lever in the released
position)
4
3
5
m-6182
3. Clevis pin
4. Hairpin cotter
5. 1/4 in. (6 mm)
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
50 operating hours or monthly, whichever occurs first
(Fig. 43). Check the tires when they are cold to get the most
accurate pressure reading.
Greasing and Lubricating the
Machine
Service Interval/Specification
Grease the areas shown at the intervals given in the Where
to Add Grease section below. Grease more frequently when
operating conditions are extremely dusty or sandy.
Grease with No. 2 general-purpose lithium-base or
molybdenum-base grease.
Applying the Grease
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Clean the grease fittings with a rag and scrape any paint
from the front of the fittings.
4. Connect a grease gun to the fitting and pump grease
into the fittings until grease begins to ooze out of the
bearings.
5. Wipe up any excess grease.
Locating Where to Apply Grease
Pressure: 15 psi (103 kPa) rear tires
25–30 psi (172–207 kPa) caster tires
1
Figure 43
1. Valve stem
Cleaning the Cooling System
Service Interval/Specification
Before each use, check and clean engine cooling system.
Remove any buildup 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.
1. Lubricate the caster wheel bearings and front spindles
every 8 operating hours (Fig. 44).
Figure 44
2. Lubricate the mower deck idler pivot, pump drive idler
pivot and pump control every 40 operating hours
(Fig. 44).
34
Page 35
Note: You’ll have to remove the carrier covers to access the
grease fitting for the deck.
3. Lubricate the PTO engagement bellcrank every 100
operating hours (Fig. 44).
Cleaning the Cooling System
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 ensure adequate cooling and correct engine
speed and reduce the possibility of overheating and
mechanical damage to the engine.
3
2
1. Fuel shut-off valve
2. Fuel filter
Figure 45
3. Clamp
1
m–6474
Draining 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.
1. Park the machine on a level surface, to ensure that the
fuel tank drains completely.
2. Disengage the PTO and set the parking brake.
3. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
4. Disconnect the spark plug wire(s) from the spark
plug(s).
5. Close the fuel shut-off valve in fuel line (Fig. 45).
6. Squeeze the ends of the hose clamp together, and slide
it up the fuel line away from fuel filter (Fig. 45).
7. Pull the fuel line off the fuel filter (Fig. 45).
8. Open the fuel shut-off valve and allow the gasoline to
drain into a fuel container or drain pan.
Note: Install a new fuel filter while the fuel tank is empty.
Refer to Replacing the Fuel Filter, page 35.
9. Install the fuel line onto the fuel filter, and slide the
hose clamp close to the filter to secure the fuel line.
Servicing the Fuel Filter
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.
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Disconnect the spark plug wire(s) from the spark
plug(s).
4. Close the fuel shut-off valve (Fig. 45).
5. Squeeze the ends of the hose clamps together and slide
them away from the filter (Fig. 45).
6. Remove the filter from the fuel lines.
7. Install a new filter and move the hose clamps close to
the filter.
8. Open the fuel shut-off valve at the fuel tank (Fig. 45).
35
Page 36
9. Check for fuel leaks and make any needed repairs.
Servicing the Hydraulic System
Replacing the Hydraulic Filter
Change the hydraulic filter:
• After the first 8 operating hours.
• After every 200 operating hours.
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
Important Do not substitute automotive oil filter or
severe hydraulic system damage may result.
3. Remove hydraulic reservoir cap and temporarily cover
opening with a plastic bag and rubber band to prevent
all hydro fluid from draining out.
4. Locate filter under engine base and place drain pan
under filter (Fig. 46).
5. Remove the old filter and wipe the filter adapter gasket
surface clean (Fig. 46).
1
3
2
9. 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. 46).
10. Clean up any spilled fluid.
11. If there is no fluid, add Mobil 1 15W-50 synthetic
motor oil or equivalent synthetic oil to approximately
1/4 inch (6 mm) below the top of reservoir baffle.
Important Use oil specified or equivalent. Other fluids
could cause system damage.
12. 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 36.
13. Recheck level and add fluid, if required. Do not
overfill.
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.
Air must be purged from the hydraulic system when any
hydraulic components, including oil filter, are removed or
any of the hydraulic lines are disconnected. The critical
area for purging air from the hydraulic system is between
the oil reservoir and each charge pump located on the top of
each variable displacement pump. Air in other parts of the
hydraulic system will be purged through normal operation
once the charge pump is primed.
1. Disengage the PTO and set the parking brake.
m–1256
Figure 46
1. Hydraulic filter
2. Gasket
6. Apply a thin coat hydro fluid to the rubber gasket on the
replacement filter.
7. Install replacement hydraulic filter onto the filter
adapter. Do not tighten.
8. Remove plastic bag from reservoir opening and allow
filter to fill with hydro fluid.
3. Adapter
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Raise the rear of the machine up onto jack stands high
enough to raise the drive wheels off the ground.
4. Check Hydraulic fluid level.
5. Start engine and move throttle control to full throttle
position. Move the speed control lever to the middle
speed position and place the drive levers into the drive
position.
If either drive wheel does not rotate, it is possible to assist
the purging of the charge pump by carefully rotating the
tire in the forward direction.
36
Page 37
Note: It is necessary to lightly touch the charge pump cap
(Fig. 47) with your hand to check the pump temperature. If
the cap is too hot to touch, turn off engine. The pumps may
be damaged if the pump becomes too hot. If either drive
wheel still does not rotate continue to next step.
Note: Keep areas around hydraulic system clean from grass
and debris build up.
Warning
2
1
m-5955
Figure 47
1. Charge pump cap 2. Socket head screw
6. Thoroughly clean the area around each of the charge
pump housings.
7. To prime the charge pump, loosen two hex socket head
capscrews (Fig. 47) 1–1/2 turns only. Make sure engine
is not running. Lift charge pump housing upward and
wait for a steady flow of oil to flow out from under
housing. Retighten capscrews. Do this for both pumps.
Note: Hydraulic reservoir can be pressurized to up to 5 psi
to speed this process.
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.
Performing the Hydro Linkage
Adjustments
Perform the following linkage adjustments when the
machine needs maintenance. Perform steps Adjust Speed
Control Linkage through Adjust Tracking. If an adjustment
is needed, do them in the order that they are listed.
8. If either drive wheel still does not rotate, stop and
repeat steps 4 and 5 on the respective pump. If wheels
rotate slowly, the system may prime after additional
running. Recheck hydraulic fluid level.
9. Allow unit to run several minutes after the charge
pumps are primed with drive system in the full speed
position.
10. Check the hydro control linkage adjustment. Refer to
Adjusting Hydro Control Linkages on page 39.
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.
Adjusting the Speed Control
Linkage
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Move the speed control lever (located on the console) to
the full forward position.
4. Check the orientation of the tabs on the ends of the
speed control crank. These tabs should be pointing
straight down at the 6 o’clock position approximately
(Fig. 49).
5. Adjust the threaded yoke at the bottom of the speed
control linkage until the tabs are at the 6 o’clock
position (Fig. 49).
37
Page 38
3
1
5
Adjusting the Neutral Control
Linkages
2
Figure 48
1. Speed control rod
2. Yoke
3. Speed control crank
6. Pull the speed control lever back to neutral.
7. Check to make sure the safety switch is depressed and
there is a 5/16 inch (8 mm) space between the actuating
tab and the switch. (Fig. 49).
8. If needed, adjust switch location to create the 5/16 inch
(8 mm) space (Fig. 49).
Figure 49
1. Actuating tab
2. 5/16 inch (8 mm) space
4. Tabs, 6 o’clock position
5. Jam nut
3. Safety switch
4
1
2
3
m–5394
Warning
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 stand when supporting machine.
• Do not use hydraulic jacks.
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Raise the rear of the machine onto jack stands to raise
the drive wheels off the ground.
4. Start the engine and move the throttle ahead to the full
throttle position.
5. Place the neutral locks in the full forward position and
move the speed control lever to the medium speed
position.
6. Hold 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.
Warning
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.
38
Page 39
7. Squeeze one drive lever until an increased resistance is
felt. This is where neutral should be.
Note: Make sure you have not reached the end of the
neutral lock slot. If you have, shorten the control lever
linkage. Refer to Adjusting the Control Rod on page 41.
Adjusting the Hydro Control
Linkages
Warning
8. If the wheel turns while holding the drive lever in
neutral, the neutral control linkages need to be adjusted
(Fig. 50). If wheel stops then go to step 12.
9. Loosen the nut against the neutral control linkage yoke
(Fig. 50).
10. Adjust the neutral control linkage until the respective
drive wheel stops while the drive lever is pulled against
the neutral spring (neutral position) (Fig. 50).
11. Turn the adjusting bolt approximately 1/4 turn
clockwise if the wheel is turning in reverse or turn the
bolt approximately 1/4 turn counter–clockwise if the
wheel is turning forward (Fig. 50).
12. Release the drive lever to the forward drive position and
squeeze back into the neutral position. Check to see if
the wheel stops. If not, repeat the above adjustment
procedure.
13. After adjustments are made, tighten the nuts against the
yokes.
14. Repeat this procedure for the opposite side.
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 stand when supporting machine.
• Do not use hydraulic jacks.
Adjusting the Left Side Linkage
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
1
1. Neutral control linkage
2. Yoke
Figure 50
3. Adjusting bolt
4. Nut
3. Raise the rear of the machine onto jack stands high
enough to raise the drive wheels off of the ground.
4. Start the engine and move the throttle ahead to the full
throttle position.
3
4
2
m–5394
5. Place the left drive lever in the full forward position.
6. Place the speed control lever in the neutral position.
7. Hold 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.
Warning
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.
39
Page 40
8. Loosen the front nut on left hydro control linkage as
shown in figure 51.
9. Turn the left rear adjusting nut counter–clockwise until
wheel rotates forward (Fig. 51).
10. 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. 51).
1
11. Turn the rear nut an additional 1/2 turn and tighten the
front nut.
Note: Make sure flat part of linkage is perpendicular to pin
part of swivel.
12. After adjusting the left hydro control linkage, move the
speed control lever forward and then back to the neutral
position.
13. Make sure the speed control lever is in the neutral
position and the tire does not rotate.
14. Repeat the adjustment if needed.
1
3
2
3
2
m–5396
Figure 52
1. Speed control lever
2. Rear pivot spring
3. spring
Adjusting the Right Side Linkage
1. Place the speed control lever in the neutral position.
2. Place the right drive lever in the full forward position.
3. Hold 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. 53).
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. 53).
m–5394
Figure 51
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
the above adjustments if necessary (Fig. 52).
6. The spring that keeps tension on the knob should
normally not need adjustment. However if an
adjustment is needed, adjust the length of spring to
1 inch (26 mm) between the washers (Fig. 53).
7. Adjust spring length by turning nut at front of spring
(Fig. 53).
40
Page 41
2
1
1
5
3 2
6
3
4
m–5403
Figure 53
1. Hydro control linkage
2. Quick track knob
3. Spring
4. 1 inch (26 mm)
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.
4
m–5388
Figure 54
1. Handle
2. Neutral lock
3. Neutral position
4. Drive lever
5. Full speed forward
6. Control rod
Tracking the Adjustment
1. Remove machine from any jack stands.
2. Check the rear tire pressure. Refer to Checking the Tire
Pressure, page 34.
3. Run the unit and 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. 55).
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 clevis pin. Rotate the rod in the rod fitting
(Fig. 54).
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. Release and engage neutral lock checking that the tire
does not rotate. Continue this process until the tire does
not rotate.
5. Place the hairpin back into clevis pin (Fig. 54).
6. Repeat this adjustment for opposite side.
1
m–5398
Figure 55
1. Quick track knob
Adjusting the Spring Anchor
Links
For medium or heavy duty drive conditions, such as
operating with a sulky on steep slopes, a higher spring force
may be required on the hydro pump control arms to prevent
the drive system from stalling.
1. Disengage the PTO and set the parking brake.
41
Page 42
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. For a heavier drive setting, relocate the spring anchor
links to either the medium or heavy duty positions
(Fig. 56). The spring anchor links are attached to the
upper rear corner of the hydro drive shields on the left
and right sides of the machine.
Note: In the medium or heavy duty positions, the drive
lever forces at the upper handle will also be increased
2
3
4
1
Figure 56
1. Spring anchor
2. Standard setting
3. Medium setting
4. Heavy duty setting
Note: Proper belt tension is 10–15 lbf. (44–67 N) with the
belt deflected 1/2 inch (13 mm) halfway between the
pulleys (Fig. 57).
1
3
4
2
m–4731
Figure 57
1. Idler pulley
2. 1/2 inch (13 mm)
deflection here
3. Assist arm
4. Front stop
8. Engage the blade control (PTO) lever.
9. Check the clearance between the bell crank and the
transmission output shaft (Fig. 58).
3
2
1
Checking the Belts
Service Interval/Specification
Check all belts after every 50 operating hours or monthly,
whichever occurs first. Look for dirt, wear, cracks, and
signs of overheating.
Replacing the Mower Belt
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Remove the knobs and the belt cover on the mower.
4. Remove the idler pulley and the worn belt (Fig. 57).
5. Install the new mower belt.
6. Install the idler pulley.
7. Engage the blade control (PTO) lever and check the belt
tension. Refer to Adjusting the Mower Belt Tension,
page 43.
4
5
6
m–3860
Figure 58
1. 1/16–1/8 inch (2–3 mm)
2. Bell crank
3. Transmission output shaft
4. Hairpin cotter
5. Clevis pin
6. Clevis
Note: The clearance should be 1/16–1/8 inch (2–3 mm).
10. Remove the hairpin cotter and the clevis pin from the
bell crank.
11. Rotate the clevis clockwise on the rod to increase the
clearance or counterclockwise to decrease it (Fig. 58).
12. Disengage the blade control (PTO) lever.
42
Page 43
Note: If the assist arm does not contact the front stop on
the mower deck (Fig. 59), adjust the clevis to bring the
bell crank closer to the transmission output shaft
(Fig. 58).
3
12
4
5
m–4731
Figure 59
1. Locknut
2. Turnbuckle
3. Rear idler pulley
4. Front position for idler
pulley
5. Belt guide
13. Check the belt guide under the engine frame for proper
adjustment (Fig. 59).
Adjusting the Mower Belt
Tension
Service Interval/Specification
Check the belt tension after the first 8 and 25 hours of
operation. Check the belt tension every 50 operating hours.
Important The belt must be tight enough to not slip
during heavy loads while cutting grass. Over tensioning the
belt will reduce the bearing life of the belt and the spindle.
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. Loosen the locknut on the turnbuckle (Fig. 59).
4. Rotate the turnbuckle toward the rear of the mower to
increase the tension on the belt. Rotate the turnbuckle
toward the front of the mower to decrease the tension
on the belt (Fig. 59).
Note: The eyebolt threads on both ends of the
turnbuckle should be engaged a minimum of 5/16 inch
(8 mm).
Note: The distance between the belt guide and the
mower belt should be 1-3/8 inch (35 mm) when you
engage the mower belt (Fig. 60). Adjust the mower belt
as necessary. The disengaged belt should not drag or
fall off the pulley when the guides are properly
adjusted.
1–3/8 inch
Figure 60
1. Belt guide
Adjusting the Blade Brake
1. Disengage the PTO and set the parking brake.
2. Stop the engine and wait for all moving parts to stop
before leaving the operating position.
3. If necessary, adjust the spring mounting bolts so that the
blade brake pad rubs against the pulley edges (Fig. 61).
3
1
2
m–47271
Figure 61
1. Spring mounting bolts
2. Blade brake pad
3. 1/8–3/16 inch (3–5mm)
4. Adjust the nut at the end of the blade brake rod until
there is 1/8–3/16 inch (3–5 mm) between the nut and
the spacer (Fig. 61).
43
Page 44
5. Engage the blades, and ensure that the blade brake pad
no longer contacts the pulley edges.
Replacing the Grass Deflector
Warning
2
4
8
1
6
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. 62). 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 62.
3. Install bolt and nut. Place the J hook end of spring
around grass deflector (Fig. 62).
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.
1
m–7868
1. Bolt
2. Spacer
3. Locknut
4. Spring
5. Spring installed
3
8
5
7
Figure 62
6. Grass Deflector
7. L end of spring, place
behind deck edge before
installing bolt
8. J hook end of spring
Wiring Diagram
INTERLOCK MODULE
A
B
BK
OR
C
D
BN
E
DELTA MODULE (1201)
R
F
GN
WIRE COLOR CODES
SW1
BLADE SWITCH
OR
(BLADE SWITCH OPENS
WHEN BLADE IS ENGAGED)
SW3
OPERATOR PRESENCE SWITCH
Y
(SWITCH CLOSED WHEN
Y
OPERATOR IS PRESENT)
GN
SW2
NEUTRAL SWITCH
(NEUTRAL SWITCH CLOSES
WHEN IN NEUTRAL)
SW4
BRAKE SWITCH
(SWITCH CLOSED WHEN
BRAKE IS OFF)
BNBU
MAG
R
GND
BK
BK
BN
BU
BLACK
BROWN
BLUE
GREEN
15 HP KOHLER
SPARK PLUG
Y
R
OR
IGNITION
MODULE
YELLOW
RED
ORANGE
44
Page 45
Hydraulic Diagram
e
CASE DRAIN
HIGH PRESSURE
High Pressure Reverse
CHARGE PUMP INLET
High
Pressure
Reverse
High
Pressure
Forward
High
Pressure
Reverse
Filter
Front of Machin
Hydraulic Tank
45
Page 46
Cleaning and Storage
1. Disengage the power take off (PTO) and stop the
engine.
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 30.
4. Change the crankcase oil; refer to Servicing the Engine
Oil, page 31.
5. Change the hydraulic filter; refer to Servicing the
Hydraulic System, page 36.
6. Check the tire pressure; refer to Checking the Tire
Pressure, page 34.
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).
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 Fuel Tank, page 35.
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 Plugs, page 32. 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.
Cover the machine to protect it and keep it clean.
Note: A fuel stabilizer/conditioner is most effective when
mixed with fresh gasoline and used at all times.
46
Page 47
Troubleshooting
g
gp
g
PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION
Engine will not start, starts hard, or
fails to keep running.
Engine loses power.
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
neutral.
4. Choke is not ON. 4. Move choke lever to ON.
5. Air cleaner is dirty. 5. Clean or replace air cleaner
element.
6. Spark plug wire is loose or
disconnected.
7. Spark plug is pitted, fouled, or
gap is incorrect.
8. Dirt in fuel filter. 8. Replace fuel filter.
9. Dirt, water, or stale fuel is in
fuel system.
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.
6. Install wire on spark plug.
7. Install new, correctly gapped
spark plug.
9. Contact Authorized Service
Dealer.
4. Remove obstruction from
cooling fins and air passages.
Engine overheats.
Machine does not drive.
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.
2. Hydrostatic fluid level low. 2. Fill hydrostatic fluid tank.
3. Traction belt is worn, loose or
broken.
4. Traction belt is off pulley.
5. Cold start kit engaged.
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.
3. Change Belt.
4. Install Belt.
5. Disengage cold start kit.
47
Page 48
PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES
g
gg
Machine moves slowly in neutral. 1. Neutral is mis-adjusted.
2. Neutral control spring is
broken or missing.
Machine tracks left or right.
Abnormal vibration.
Uneven cutting height.
1. Tire pressure is not correct. 1. Adjust tire pressure.
2. Tracking knob not adjusted
correctly.
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).
1. Adjust hydro linkages.
2. Replace neutral control
spring.
2. Adjust tracking knob.
1. Install new cutting blade(s).
3. Tighten engine mounting bolts.
4. Tighten the appropriate pulley.
Dealer.
Dealer.
Blades do not rotate.
3. Mower is not level. 3. Level mower from side-to-side
and front-to-rear.
4. Underside of mower is dirty. 4. Clean the underside of the
mower.
5. Tire pressure is incorrect. 5. Adjust tire pressure.
6. Blade spindle bent. 6. Contact Authorized Service
Dealer.
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.
48
Page 49
Page 50
Page 51
Page 52
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 Products if defective in materials or workmanship.
The following time periods apply from the date of purchase:
Products
• All Products 1 year
• All Spindles 2 years parts and labor;
• Engines/Hydraulic Systems* on
the following:
Outfront and Mid-Mount Z’s
ProLine Mid-Size Mowers
Groundsmaster
Backpack Blowers
• Deck Shells (36″–72″) on the
following:
ProLine Mid-Size Mowers
Mid-Mount Z’s
• Electric Clutch on 500 Series
Mid-Mount Z’s
This warranty includes the cost of parts and labor, but you must
pay transportation costs.
This warranty applies to:
• Outfront and Mid-Mount Z’s
• ProLine Mid-Size Mowers
• Groundsmaster Riding Mowers
• Turf Maintenance Equipment
• Debris Management Equipment
* Some engines used on Toro LCE Products are warranted by the
engine manufacturer.
®
Riding Mowers
Warranty Period
third year, parts only
2 years
2 years
2 years
Instructions for Obtaining Warranty Service
If you think that your Toro 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. U.S.
Customers may also call 800-348-2424.
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, contact us at:
LCB Customer Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
888-577-7466 (U.S. customers)
877-484-9255 (Canada customers)
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.
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. D
Loading...