Toro 30611 Operator's Manual

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FORM NO. 3322–489

ProLine

Traction Unit

Model No. 30611 – 990001 & Up

Operator’s Manual

IMPORTANT: Read this manual carefully. It contains information about your

safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.

Introduction

Thank you for purchasing a Toro product. All of us at Toro want you to be completely satisfied

with your new product, so feel free to contact your local Authorized Service Dealer for help with service, genuine replacement parts, or other information you may require.

Whenever you contact your Authorized Service Dealer or the factory, always know the model and serial numbers of your product. These numbers will help the Service Dealer or Service Representative provide exact information about your specific product. You will find the model and serial number plate located in a unique place on the product as shown below

The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, 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 the recommended precautions are not followed.

WARNING signals a hazard that may cause serious injury or death if the recommended precautions are not followed.

CAUTION signals a hazard that may cause minor or moderate injury if the recommended precautions are not followed.

Two other words are also used to highlight information. “Important” calls attention to special mechanical information and “Note” emphasizes general information worthy of special attention.

m–2196

1. Model

For your convenience, write the product model and serial numbers in the space below.

Model No:

Serial No.

Read this manual carefully to learn how to operate and maintain your product correctly. Reading this manual will help you and others avoid personal injury and damage to the product. Although we design, produce and market safe, state-of-the-art products, you are responsible for using the product properly and safely. You are also responsible for training persons, who you allow to use the product, about safe operation.

and Serial Number Plate

The left and right side of the machine is determined from the normal operator’s position.

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.

The Toro Company – 1998

Contents

Page

Safety 2.

Gasoline and Oil 10

Set-up 12

Operation 16

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Safe Operation Practices for Ride-on (riding)

Rotary Lawnmower Machines2. . . . . . . .

Slope Chart 5

Symbols Glossary7. . . . . . . . . . . . . . . . . . .

Symbols Glossary8. . . . . . . . . . . . . . . . . . .

Symbols Glossary9. . . . . . . . . . . . . . . . . . .

Recommended Gasoline10. . . . . . . . . . . . . .

Stabilizer/Conditioner 11 Filling the Fuel Tank 11 Check Engine Oil Level 11

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Loose Parts 12 Install Seat 13 Install Steering Wheel 13 Install Rear Weights 13 Activate the Battery 14 Install the Battery 15 Check Engine Oil 15 Check Hydraulic System Fluid 15

Think Safety First 16 Starting and Stopping

the Engine 16 Operating the Power Take Off (PTO) 17 Driving Forward or Backward 17 Parking Brake 18 Implement Lift Lever 18 The Safety Interlock System 19 Positioning the Seat 19 Pushing or T

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owing the Machine19. . . . . . . .

Page

Maintenance 20

Service Interval Chart 20 Belt Guard 21 Air Cleaner 21 Engine Oil 23 Spark Plug 25 Greasing and Lubrication 26 Brake 28 Fuel Filter 29 Tire Pressure 29 Cleaning the Cooling System 30

Adjust Belts30. . . . . . . . . . . . . . . . . . . . . . . .

Replace Belts31. . . . . . . . . . . . . . . . . . . . . . .

Adjust Lift Cylinder and Counterbalance Springs

31 Adjust T Adjust Electric Clutch 33 Check Hydraulic System Fluid 34 Change Hydraulic System Oil 34 Change Hydraulic Oil Filter 35 Adjust Steering 35 Hydraulic Schematic 36 Change Front Axle Oil 37 Battery 37 Wire Harness Service 38 Wiring Diagram 39 Cleaning and Storage 40

Troubleshooting 42

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ransmission Neutral32. . . . . . . . . . .

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Safety

Safe

Operation Practices for Ride-on (riding) Rotary Lawnmower Machines

Training

1. Read the instructions carefully. Be familiar with

the controls and the proper use of the equipment.

2. Never allow children or people unfamiliar with

these instructions to use the lawnmower. Local regulations may restrict the age of the operator.

3. Never mow while people, especially children, or

pets are nearby.

4. Keep in mind that the operator or user is

responsible for accidents or hazards occurring to other people or their property.

5. Do not carry passengers.

6. All drivers should seek and obtain professional

and practical instruction. Such instruction should emphasize:

Preparation

1. While mowing, always wear substantial

footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

2. Thoroughly inspect the area where the

equipment is to be used and remove all objects which may be thrown by the machine.

3. WARNING – Petrol is highly flammable.

• Store fuel in containers specifically

designed for this purpose.

• Refuel outdoors only and do not smoke

while refuelling.

• Add fuel before starting the engine. Never

remove the cap of the fuel tank or add petrol while the engine is running or when the engine is hot.

• If petrol is spilled, do not attempt to start

the engine but move the machine away from the are of spillage and avoid creating any source of ignition until petrol vapors have dissipated.

• the need for care and concentration when

working with ride-on machines;

• control of a ride-on machine sliding on a

slope will not be regained by the application of the brake. The main reasons for loss of control are:

insufficient wheel grip; being driven too fast; inadequate braking; the type of machine is unsuitable for its

task; lack of awareness of the effects of

ground conditions, especially slopes; incorrect hitching and load distribution.

• Replace all fuel tanks and container caps

securely.

Replace faulty silencers.

5. Before using, always visually inspect to see that

the blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

6. On multi–bladed machines, take care as rotating

one blade can cause other blades to rotate.

Safety

Operation

1. Do not operate the engine in a confined space

where dangerous carbon monoxide fumes can collect.

2. Mow only in daylight or in good artificial light.

3. Before attempting to start the engine, disengage

all blade attachment clutches and shift into neutral.

4. Do not use on slopes of more than:

• Never mow side hills over 5

• Never mow uphill over 10

• Never mow downhill over 15

Note: Slope angle is calculated as in

5.4.2.3.2.

5. Remember there is no such thing as a “safe”

slope. Travel on grass slopes requires particular care. To guard against overturning:

• do not stop or start suddenly when going up

or downhill;

•

engage clutch slowly in gear, especially when travelling downhill;

• machine speeds should be kept low on

slopes and during tight turns;

• stay alert for bumps and hollows and other

hidden hazards;

• never mow across the face of the slope,

unless the lawnmower is designed for this purpose.

6. Use care when pulling loads or using heavy

equipment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely control.

• Do not turn sharply. Use care when

reversing.

, always keep machine

7. Watch out for traffic when crossing or near

roadways.

8. Stop the blades rotating before crossing surfaces

other than grass.

9. When using any attachments, never direct

discharge of material toward bystanders nor allow anyone near the machine while in operation.

10. Never operate the lawnmower with defective

guards, shields or without safety protective devices in place.

11. Do not change the engine governor settings or

overspeed the engine. Operating the engine at excessive speeds may increase the hazard of personal injury.

12. Before leaving the operator’

s position:

• disengage the power take-off and lower the

attachments;

• change into neutral and set the parking

brake;

• stop the engine and remove the key.

13. Disengage drive to attachments, stop the engine,

and disconnect the spark plug wire(s) or remove the ignition key

• before cleaning blockages or unclogging

chute;

• before checking, cleaning or working on the

lawnmower;

• after striking a foreign object. Inspect the

lawnmower for damage and make repairs before restarting and operating the equipment;

• if the machine starts to vibrate abnormally

(check immediately).

14. Disengage drive to attachments when

transporting or not in use.

• Use counterweight(s) or wheel weights

when suggested in the instruction handbook.

Safety

15. Stop the engine and disengage drive to

attachment

• before refuelling;

• before removing the grass catcher;

• before making height adjustment unless

adjustment can be made from the operator’s position.

16. Reduce the throttle setting during engine run-out

and, if the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

Maintenance and storage

1. Keep all nuts, bolts and screws tight to be sure

the equipment is in safe working condition.

2. Never store the equipment with petrol in the tank

inside a building where fumes may reach an open flame or spark.

Sound Pressure

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 88 dB(A), based on measurements of identical machines per ANSI B71.5–1984 procedure.

Sound Power

This unit has a power level of: 104 dB(A)/1pW, based on measurements of identical machines per Directive 84/538/EEC and amendments.

Vibration Level

This unit has a maximum hand-arm vibration level of

6.1 m/s2, and whole body vibration level of

0.16 m/s2, based on measurements of identical machines per ISO 5349.

3. Allow the engine to cool before storing in any

enclosure.

4. To reduce the fire hazard, keep the engine,

silencer, battery compartment and petrol storage area free of grass, leaves, or excessive grease.

5. Check the grass catcher frequently for wear or

deterioration.

6. Replace worn or damaged parts for safety.

7. If the fuel tank has to be drained, this should be

done outdoors.

8. On multi-bladed machines, take care as rotating

one blade can cause other blades to rotate.

9. When machine is to be parked, stored or left

unattended, lower the cutting means unless a positive mechanical lock is used.

Safety

Slope

Read all safety instructions on pages 2–9.

Chart

Safety

Symbols

Safety alert triangle– symbol within triangle indicates a hazard

Safety alert symbol

Read operator’s manual

Consult technical manual for proper service procedures

Glossary

Fire, open light & smoking prohibited

Fire or open flame

Explosion

Do not dispose of lead battery in garbage

Shut off engine & remove key before preforming maintenance or repair work

Caustic liquids, chemical burns to fingers or hand

Caution, toxic risk

Eye protection must be worn

Stay a safe distance from the machine

Stay safe distance from machine

Stay safe distance from machine, riding mower

Stay safe distance from machine

First aid, flush with water

Keep children away

from battery

Safety

Symbols Glossary

Do not open or remove safety shields while engine is running

Thrown or flying objects,

whole body exposure

Thrown or flying objects,

whole body exposure

Keep guards and safety sheilds in place

Severing of toes & fingers, rotary mower blade

Stored energy hazard, kickback or upward motion

aite until all machine components have completely stopped before touching them

Machine rollover riding mower

o operate machine on a

T slope, use with 16kg weight

kit & operate with deck lowered

Cutting of fingers or hand

Cutting of foot

Hot surface, burns to fingers or hands

Severing of fingers or hand-engine fan

Operating machine on a slope less than 10 , operate with deck lowered on downhill, riding mower

Disengage PT brake, turn off engine and

remove key before leaving operator’s position

Blade cutting elementheight adjustment

Blade retaining bolts must be

Torqued to 1

O, set parking

15–149 N.m

(mm)

Symbols Glossary

Safety

Fast

Slow

Decreasing/Increasing

On/Run

Off/stop

Engine start

Engine Oil

Battery

Gas T

ank Level

Lock

Engine stop

Choke

Brake system

Parking brake

Power take off (PT

Engage

Disengage

Attachmant Raise

Attachment Lower

Gasoline and Oil

Recommended

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

IMPORTANT: Never use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with gasoline.

POTENTIAL HAZARD

Gasoline

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.

Add gasoline to the fuel tank until the level is 1/4” to 1/2” (6 mm 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.

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Always place gasoline containers on the

ground away from your vehicle before filling.

• Do not fill gasoline containers inside a

vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge.

• When practical, r

equipment from the truck or trailer and refuel the equipment with its wheels on the round.

emove gas–power

• 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 and Oil

Stabilizer/Conditioner

Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine:

• Keeps gasoline fresh during storage

• Cleans the engine while it runs

• Eliminates gum-like buildup in the fuel system,

which causes hard starting

IMPORTANT: Never use fuel additives containing methanol or ethanol.

Filling

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

2. Clean around each fuel tank cap and remove the

3. Install fuel tank caps securely. Wipe up any

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 23.

the Fuel T

cap. Add unleaded regular gasoline to both fuel tanks, 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 tanks completely full.

gasoline that may have spilled.

ank

Engine Oil Level

Set-up

Loose

Parts

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

DESCRIPTION QTY. USE

Spacer Steering wheel Roll pin 1/4 x 2-1/2” (64 mm)

Seat Bolt 5/16-18 x 1” (25 mm) Lock nut 5/16-18 R-clamp

Weight Bolt 1/2–13 x 3-1/2” (89 mm) Washer 1/2” (13 mm) Lock washer 1/2” (13 mm) Nut 1/2”

Carriage bolt 1/4-20 x 3/4” (19 mm) Wing nut 1/4-20

1 1 1

1 4 4 1

2 4 4 4 4

2 2

Install steering wheel

Install seat

Install on rear weight

Install battery cables

Operator’ Parts catalog Registration card

s Manual

1 1 1

Rear before operating machine

Fill out and return to T

oro

Set-Up

Install

Seat

1. Position seat assembly onto seat plate aligning

mounting holes (Fig. 1).

2. Slide wire clamp over seat switch wire (Fig. 1).

3. Using left front hole, loosely secure wire clamp

and seat to seat base with capscrews and lock nuts (Fig. 1).

4. Mount seat to seat base with (3) remaining bolts

and lock nuts.

5. Rout seat switch wire thru slot in seat plate and

plug connector onto seat switch (Fig. 1).

6. Tighten all lock nuts and check operation of seat.

7. Make sure wire harness is clear of lift arm and

all moving parts.

Install

Steering Wheel

1. Move rear wheels so they point straight ahead.

2. Slide spacer and steering wheel onto steering

shaft aligning mounting holes. Check that logo on steering cap points forward.

3. Secure steering wheel to shaft with roll pin

(Fig. 2).



Figure 2

1. Spacer

2. Roll

Steering Wheel

1. Seat

2. R-clamp

plate

Figure 1

Seat switch wire

Seat switch connector



Install

Rear W

eights

1. Attach two (2) weights onto existing weight with

(4) 1/2 x 3-1/2” (89 mm) bolts, (4 ea.) 1/2” washers, 1/2” lock washers and 1/2”nuts (Fig. 3).

1. Weight

2. Bolt

1/2–13 x 3-1/2”

(89 mm)

Figure 3

3. Washer nut

, lock washer and



Set-Up

Activate

the Battery

Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet.

1. If already installed, remove the battery from the

holder.

POTENTIAL HAZARD

• Battery electrolyte contains sulfuric acid

which is a deadly poison and it causes severe burns.

WHAT CAN HAPPEN

• If you carelessly drink electrolyte you could

die or if it gets onto your skin you will be burned.

HOW TO AV

OID THE HAZARD

• Do not drink electrolyte and avoid contact

with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

2. Remove filler caps from the battery. Slowly pour

electrolyte into each cell until the electrolyte level is up to the lower part of the tube (Fig. 4).

1262

Figure 4

1. Filler

2. Electrolyte

caps

Lower part of the tube

3. Leave the covers off and connect a 3 to 4 amp

battery charger to the battery posts (Fig. 5). Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts).

1. Positive

Negative post

post

Figure 5

Charger red (+) wire

Charger black (–) wire

1254

Set-Up

5 7

POTENTIAL

• Charging battery pr

HAZARD

oduces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

4. When the battery is fully charged, disconnect the

charger from the electrical outlet then from the negative and positive battery posts (Fig. 5).

5. Slowly pour electrolyte into each cell until the

level is up to the lower part of the tube (Fig. 4) and install covers.

6. Install the battery into the holder.

Install

the Battery

IMPORTANT: Activate battery with electrolyte and charge before installing.



Figure 6

1. Clamp

2. Support

Check

rod Wing nut Positive battery cable

Engine Oil

Negative battery cable

Carriage Bolt

7. T

erminal Boot

The engine is shipped with 4 pints of oil in the crankcase; however

, oil level must be checked before and after the engine is first started. Check oil level; refer to Checking Oil Level, page 23.

1. Mount battery on battery support with terminal

posts toward gas tank (Fig. 6).

2. Secure battery with clamp, support rod and wing

nut (Fig. 6).

Note: DO NOT OVERTIGHTEN.

3. Slide the red terminal boot onto the red battery

cable (Fig. 6).

4. Install the positive battery cable to positive (+)

battery terminal and the negative battery cable to the negative (–) battery terminal and secure with carriage bolts and lock nuts (Fig. 6).

Check

Hydraulic System Fluid

The hydraulic system is shipped with approximately 5 quarts of 10W–30 engine oil; however, oil level must be checked before the engine is first started. Check oil level; refer to Check Hydraulic System Fluid, page 34.

Operation

Think

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

Become familiar with all the controls before you start the engine and operate the machine.

Starting

Safety First

and Stopping

the Engine

Starting

1. Make sure spark plug wire(s) are installed on

spark plug(s).

2. Move the traction pedal to neutral, set the

parking brake and move the PTO switch to “OFF.”

Stopping

1. Move the throttle lever to “SLOW” (Fig. 7). Note: If the engine has been working hard or

is hot, let it idle for a minute before turning the ignition key “OFF.” This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to “OFF.”

2. Turn the ignition key to “OFF” (Fig. 7).

3. Set the parking brake.

4. Pull wire off spark plug(s) to prevent possibility

of accidental starting before storing machine.

3. Move the choke control to the “CHOKE”

position before starting a cold engine. Note: A warm or hot engine may not require

any choking.

4. Rotate ignition key to “START.” When engine

starts, release key, gradually move choke to run and regulate throttle to desired speed.

IMPORTANT: To prevent overheating of the starter motor, do not engage starter longer than 10 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging starter motor again.

1. Traction

2. PTO switch

pedal

Ignition switch



Figure 7

4. Choke

5. Throttle

Operation

Operating

the Power T

ake Off

(PTO)

The power take off (PTO) switch engages and disengages power to the electric clutch.

Engaging the PTO

1. Release pressure on the traction pedal to stop

movement. (Fig. 8).

2. To engage lift cover and move the PTO switch to

the “ON” position (Fig. 8).

Disengaging the PTO

1. Closing the cover moves the PTO switch to the

“OFF” position (Fig. 8).

Forward

1. To go forward, place your foot on the traction

pedal (Fig. 8).

2. Release the parking brake.

3. Slowly press on the upper pad of the traction

pedal to move forward (Fig. 8).

Backward

1. To go backward, place your foot on the traction

pedal (Fig. 8).

2. Release the parking brake.

3. Slowly press on the lower pad of the traction

pedal to move rearward (Fig. 8).

Stopping the Machine

To stop the machine, release pressure on the traction pedal, move the PTO switch to “OFF” and turn the ignition key to “OFF” to stop the engine and remove the key. Also set the parking brake if you leave the machine unattended; refer to Setting the Parking Brake, page 18.

Figure 8

1. Traction

2. PTO switch

Driving

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Move the throttle control to the “FAST” position for best performance.

pedal

Ignition switch

Forward or Backward

4. Choke

5. Throttle



POTENTIAL HAZARD

• Someone could move or attempt to operate

the machine while it is unattended.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the machine.

HOW TO AV

•

Always r parking brake when leaving the machine unattended, even if just for a few minutes.

OID THE HAZARD

emove the ignition key and set the

Operation

Parking Brake

Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

1. Release pressure on the traction pedal to stop

movement.

2. Lift the parking brake lever up (Fig. 9) to apply

the parking brake.

Releasing the Parking Brake

1. Move the parking brake lever down (Fig. 9) to

the released the parking brake.

Implement

Lift Lever

The implement lift lever (Fig. 9) is used to raise and lower various attachments.

Note: When done using implement engage

lock bracket and tighen knob.

Raising Attachments

1. Remove pressure from traction pedal to stop the machine.

2. Loosen the lock bracket knob. Move bracket back and tighten knob (Fig. 10).

3. Pull implement lift lever (Fig. 9) rearward to raise attachment to the desired height.

Lowering Attachments

1. Remove pressure from traction pedal to stop the machine.

1. Parking

brake

Figure 9

Implement lift lever



2. Loosen the lock bracket knob. Move bracket back and tighten knob (Fig. 10).

3. Push implement lift lever (Fig. 9) forward to lower attachment.

Figure 10

1. Lock

Bracket

Implement lift lever

3. Knob



The

Safety Interlock System

Positioning

Operation

the Seat

Understanding the Safety Interlock System

The safety interlock system is designed to prevent the engine from rotating or starting unless:

• The traction pedal is in neutral

• The power take off (PT

The safety interlock system is designed to stop the engine if you rise from the seat when the power take off (PTO) is engaged or the motion control is not in neutral.

O) is disengaged

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

1. Switch the power take off (PTO) “ON”. Now

turn the key to “START”; the engine should not rotate.

2. Turn the power take off (PTO) “OFF” and move

the motion control (forward or reverse). Now turn the ignition key to “START”; the engine should not rotate.

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

1. To adjust the seat move lever on left side of seat

rearward (Fig. 11).

2. Slide seat to desired position and release lever to

lock seat into position.



1. Seat

adjustment lever

Pushing

or T

Figure 1

owing the

3. Set the parking brake, move the power take off

(PTO) to disengaged, motion control to neutral and start the engine. While the engine is running, engage the power take off (PTO) and rise slightly from the seat; the engine should stop.

4. Set the parking brake, move the power take off

(PTO) to disengaged, motion control to neutral and start the engine. While the engine is running, slowly move the motion control (forward or reverse) ; the engine should stop.

IMPORTANT: The unit can be started when all contr operator in the seat, for servicing.

ols ar

e in a safe position, without the

Machine

In an emergency, the traction unit can be pushed or towed for a very short distance. Toro does not recommend this as standard procedure.

IMPORTANT: Do not push or tow the traction unit faster than 2 to 3 mph because transmission may be damaged. If traction unit must be moved a considerable distance, transport on a truck or trailer.

1. To push or tow forward, the traction pedal must

be fully depressed forward.

2. To push or tow in reverse, the traction pedal

must be fully depressed in reverse.

Maintenance

Service

Oil—check level Oil—change* Initial X X Oil Filter–change* (100 hours, every

other oil change) Safety System—check Brake—check X X X Engine—clean outside and cooling fins Bearings\Bushings—grease* X X Foam Air Cleaner—clean* Paper Air Cleaner—clean* Paper Air Cleaner—replace* Spark Plug(s)—check Belts—check for wear/cracks Fuel Filter—replace Battery–check electrolyte level T

ires—check pressure Hydraulic System–change oil (250 hrs) Hydraulic System–change filter (250 hrs) Front Axle–change oil (500 hours) Chipped Surfaces—paint

Interval Chart

Operation

Each

Use8Hours25Hours50Hours

X X

X X X

X X X X

X X

X X X X

100

Hours

X X

200

Hours

X X

X X X X

Storage

Service

X X

More often in dusty

POTENTIAL HAZARD

• If you leave the key in the ignition switch, someone could start the engine.

WHAT CAN HAPPEN

• Accidental starting of the engine could seriously injure you or other bystanders.

HOW TO AV

• Remove the key from the ignition switch and pull the wire(s) off the spark plug(s)

, dirty conditions

OID THE HAZARD

before you do any maintenance. Also push the wire(s) aside so it does not accidentally contact the spark plug(s).

Maintenance

Belt

Guard

You will have to remove the belt guard to perform maintenance under seat and engine cover.

Removing Belt Guard

1. Raise seat and remove center bolt (Fig. 12).

2. Remove guard from interlock rear lip in rear of

opening (Fig. 12).

3. Lift guard out (Fig. 12).

Installing Belt Guard

1. Raise seat.

2. Interlock rear lip of belt guard into rear of

opening (Fig. 12).

3. Secure center bolt into speed nut and belt guard

(Fig. 12).

Air

Cleaner

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

Paper Element: Replace after every 100 operating hours.

Note: Service the air cleaner more frequently

(every few hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper Elements

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unscrew the knob and remove the air cleaner cover (Fig. 13).

1. Belt

Rear lip

Speed nut

guard

Figure 12

2108

Center Bolt 1/4–20 x 7/8” (22 mm)

1. Wing

2. Cover

3. Filter

nut

Figure 13

4. Pre-filter

Filter Base



Maintenance

4. Carefully slide the foam element off the paper

element (Fig. 13).

5. Unscrew the cover nut and remove the cover and

paper element (Fig. 13).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and

warm water. When the element is clean, rinse it thoroughly.

B. Dry the element by squeezing it in a clean

cloth (do not wring).

C. Put one or two ounces of oil on the element

(Fig. 14). Squeeze the element to distribute the oil.

IMPORTANT: Replace the foam element if it is torn or worn.

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 15).

B. Inspect the element for tears, an oily film,

and damage to the rubber seal.

IMPORTANT: Never clean the paper element with pressurized air or liquids, such as solvent, gas, or kerosene. Replace the paper element if it is damaged, or cannot be cleaned thoroughly.

1. Foam

element

Figure 14

2. Oil

m–1213

Figure 15

1. Paper

element

Rubber seal

Installing the Foam and Paper Elements

1. 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. Carefully slide the foam element onto the paper

air cleaner element (Fig. 13).

2. Place the air cleaner assembly onto the air cleaner base (Fig. 13).

3. Install the air cleaner cover and secure with cover nut (Fig. 13).

4. Reinstall belt gurard. See Installing Belt Guard on page 21.

Maintenance

Engine

Oil

Service Interval/Specification

Change oil:

• After the first 8 operating hours.

• After every 50 operating hours.

Note: Change oil more frequently when

operating conditions are extremely dusty or sandy.

Oil Type: Detergent oil (API service SF, SE/CC, CD or SE)

Crankcase Capacity: w/filter, .94 l (4 pints) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

Checking Oil Level

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Park the machine on a level surface, disengage

the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Clean around the oil dipstick and oil fill

(Fig. 16) so dirt cannot fall into the filler hole and damage the engine.

4. Pull the oil dipstick out and wipe the metal end

clean (Fig. 16).

5. Slide the oil dipstick fully into the dipstick tube

(Fig. 16). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler hole to raise the level to the “FULL” mark.

IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged.

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

6. Reinstall belt gurard. See Installing Belt Guard

on page 21.



Figure 16

1. Oil

dipstick

Oil fill

Metal end

Maintenance

Changing/Draining Oil

1. Start the engine and let it run five minutes. This

warms the oil so it drains better.

2. Park the machine so that the drain side is slightly

lower than the opposite side to assure the oil drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

3. Place a pan below the oil drain. Remove the oil

drain plug (Fig. 17).

4. When oil has drained completely, install the oil

drain plug. Note: Dispose of the used oil at a certified

recycling center.

Change Oil Filter Service Interval/Specification

Replace the oil filter every 100 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/Draining Oil, page 24.

2. Remove the old filter and wipe the filter adapter (Fig. 17 and 18) gasket surface.

3. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 18).



Figure 17

1. Oil

drain plug

Oil filter

5. Slowly pour approximately 80% of the specified

amount of oil into the filler tube (Fig. 16). Now check the oil level; refer to Checking Oil Level, page 24. Slowly add additional oil to bring to “FULL” mark on dipstick.

Figure 18

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. 18).

5. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 24.

1256

Maintenance

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: Champion RC 12YC (or equivalent) Air Gap: 0.040 in. (1 mm)

Removing the Spark Plug(s)

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

4. Rotate tank and set in hood to prevent fuel

spilling.

5. Push out plastic cover from access hole in plate

between engine and gas tank.

6. Pull the wire(s) off the spark plug(s). Now clean

around the spark plug(s) to prevent dirt from falling into the engine and potentially causing damage.

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



3. To gain access to the rear spark plug the gas tank

must be removed (Fig. 19).

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• 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 drain gasoline near an open flame or

where gasoline fumes may be ignited by a spark.

• Never smoke a cigarette, cigar or pipe.

Figure 19

1. Fuel

tank

Opening for access

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 20).

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 r a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side

electrodes (Fig. 20). Bend the side electrode (Fig. 20) if the gap is not correct.

eplace the spark plug(s) when it has:

Maintenance

1. Center

Side electrode

Figure

electrode insulator

(0.040 in.)

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 17 N m (12 ft. lb).

3. Push the wire(s) onto the spark plug(s) (Fig. 19).

Greasing

and Lubrication

Service Interval/Specification

Grease all bearings and bushings every 25 operating hours. Grease more frequently (daily) when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose lithium base grease.

How to Grease

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

2. Clean the grease fittings with a rag. Make sure to scrape any paint off the front of the fitting(s).

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

4. Wipe up any excess grease.

4. Push plastic cover into access hole in plate

between engine and gas tank.

5. Lift fuel tank and attach fuel hose, secure with

hose clamp.

6. Rotate fuel tank into position, hook straps into

lower bracket and secure with capscrews and lock nuts.

7. Reinstall belt gurard. See Installing Belt Guard

on page 21.

Where to Add Grease

1. Lubricate the wheel bearings (Fig. 21).



Figure 21

Maintenance

2. Lubricate spindles, steering shaft and pivot

(Fig. 22).



Figure 22

3. Lubricate the axle bearings (Fig. 23). Once a year, grease front wheel hub to prevent the

formation of rust and to simplify future wheel removal.

4. Lubricate the traction pedal bushings with a few

drops of SAE 10W–30 oil or dry spray lube and the steering shaft (Fig. 24).



Figure 24

Figure 23



Maintenance

Brake

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

Checking the Brake

1. Park the machine on a level surface, disengage

the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Drive wheels must lock when the brake is

applied. Adjustment is required if the wheels turn and do not lock; refer to Adjusting the Brake, page 28.

3. Release the brake, wheels should rotate freely.

4. If both conditions are met no adjustment is

required.

IMPORTANT: With the parking brake released, the drive wheels must rotate freely. If brake action and free wheel rotation cannot be achieved contact your service dealer immediately.

Adjust the Brake

If drive wheels do not rotate freely when brake lever is in the OFF position, or brake does not hold when lever is in the ON position, an adjustment is required.

1. Move brake lever to the ON position.

Measure distance between disc brake actuating arm and stop pin on axle bracket assembly (Fig. 25). Distance should be less than 1/4 inch (6 mm).

3. If distance is greater than 1/4 inch (6 mm), tighten locknut to decrease distance between actuating arm and stop pin (Fig. 25).

4. With the brake lever OFF, check clearance between brake pads and disc with a feeler gauge (Fig. 25). Proper clearance is approximately .010 inch (.25 mm).

5. The actuating arm should be no more than 3/8 inch (10 mm) away from stop with brake lever in the ON position.

6. Check the brake operation again; refer to Checking the Brake, page 28.

7. Check adjustment. Drive wheels should rotate freely when brake lever is in the OFF position.

1. Brake

Stop pin

Lock nut

actuating arm

Figure 25

5. Disc

Brake pad (2)

1/4 inch (6mm)



Maintenance

Fuel

Filter

Service Interval/Specification

Replace the fuel filter after every 100 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 power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Have a container ready to drain fuel from the

tank. It is best to change fuel filter when fuel tank is almost empty.

3. Loosen hose clamps and slide them up the hose,

away from the filter (Fig. 26).

4. Remove the filter from the fuel lines (Fig. 26).

5. Install a new filter, if the filter has an arrow,

install with arrow pointing toward the carburetor.

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. 27). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: .103 kPa (15 psi) front and rear



Figure 27

1. Valve

stem

6. Move the hose clamps close to the filter and

tighten.

Figure 26

1. Hose

clamp

Fuel line

3. Filter

2261

Maintenance

Cleaning

the Cooling System

Service Interval/Specification

Before each use, remove grass clippings, dirt and grime from the entire machine, muffler and engine air intake screen Every 100 operating hours clean dirt and chaff from the engine cylinder head fins and blower housing. This will help insure adequate cooling and reduce the possibility of overheating and mechanical damage to the engine.

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Open hood and pull spark plug wire(s) off.

3. To avoid overheating and possible engine

damage clean, grass, dust, dirt and oil from outside of engine, air intake screen and muffler.

4. To clean cylinder head fins, remove engine from

chassis and remove cooling shrouds. Make sure cooling shrouds are re-installed before operating engine.

5. Reinstall belt gurard. See Installing Belt Guard

on page 21.

Adjust

If belt slippage occurs, idler pulleys must be adjusted to increase belt tension.

1. Disengage the power take off (PTO), set the

2. Raise seat and remove belt guard. See Removing

3. Measure distance from bottom of spacer on

4. Unhook tension spring from side of frame

5. To adjust, remove cotter pin and washer securing

6. Slide link off mounting pin and select new hole

7. Reposition link onto spring anchor and secure

Belts

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

Belt Guard on page 21.

pulley mounting screw to bottom of slot in idler adjustment link. Distance should be 1/4 inch (6 mm) or less (Fig. 28).

(Fig. 28).

idler adjustment link to spring anchor (Fig. 28).

until bottom of spacer is within 1/4 inch from bottom of slot (Fig. 28).

with washer and cotter pin (Fig. 28).

8. Reinstall belt gurard. See Installing Belt Guard on page 21.



Figure 28

1. 1/4

in (6 mm) space

Idler adjustment

Maintenance

Replace

Belts

To replace traction or jackshaft belt, use the following procedures and belt routing diagram (Fig. 29).

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

3. Clutch anchor bolt must be removed, and clutch

unplugged from wire harness before traction belts can be removed.

4. Release tension in idler pulleys before removing

or installing belts (Fig. 28).

5. Install belts, route traction belt over transmission

as shown (Fig. 29).

6. Install clutch anchor bolt and plug in connector.

Adjust

Lift Cylinder and

Counterbalance Springs

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Start engine and lower lift arms (cutting unit)

until lift cylinder is fully extended and lift (cutting unit) is fully lowered.

3. Measure distance between cylinder jam nuts and

cylinder pivot pin (Fig. 30). Distance should be approximately 2-1/4 inch.

4. Loosen jam nuts and adjust, if necessary, to

attain needed clearance.

IMPORTANT: To avoid damage reinstall clutch anchor bolt before connecting wire.

7. Adjust belt tension; refer to Adjust Belts page

30.

8. Reinstall belt gurard. See Installing Belt Guard

on page 21.



Figure 29

1. Jackshaft

2. T

Jackshaft pulley

transmission pulley

belt

raction belt

Idler pulley

Clutch pulley

Engine pulley

1. Jam

nut

Cylinder pivot pin

Counterbalance spring

Figure 30



Adjustment nut Lift arm “T” hook

Maintenance

5. Start engine and raise lift arms (cutting unit)

until lift cylinder is fully retracted and lift (cutting unit) is fully raised.

6. Check distance between clevis pin and bottom

hooks of springs (Fig. 28). Distance should be 1/4 inch or less.

7. Adjust nut on lift arm “T” hook to obtain

required distance.

8. Reinstall belt gurard. See Installing Belt Guard

on page 21.

Adjust Transmission Neutral

The machine must not creep when traction pedal is released. If it does creep, an adjustment is required.

1. Park machine on a level surface, lower cutting unit and shut engine off. Disengage the PTO and engage the parking brake.

2. Raise seat and remove belt guard. See Removing Belt Guard on page 21.

3. Jack up front of machine until tires are off shop floor. Support machine with jack stands to prevent it from falling accidentally.

4. Loosen lock nut on adjustment cam (Fig. 32).

5. Start engine and rotate adjusting cam in either

direction until wheels stop rotating (Fig. 32).



1. 1/4

inch (6 mm) clearance

Clevis pin & cotter pin

Figure 31

Lift bracket

POTENTIAL HAZARD

• Engine must be running so transmission

neutral adjustment can be performed.

WHAT CAN HAPPEN

• Contact with moving parts or hot surfaces

may cause personal injury.

HOW TO AV

OID THE HAZARD

• Keep hands, feet, face and other body parts

away from rotating parts, muffler and other hot surfaces.

Maintenance

Figure 32

1. Adjustment

cam

Lock nut

6. Stop engine and tighten lock nut to secure

adjustment (Fig. 32).

7. Start engine and check adjustment. Repeat

adjustment, if necessary.

8. Stop engine. Remove jack stands and lower

machine to the shop floor. Test drive the machine to be sure it does not creep.



Adjust

Electric Clutch

The clutch is adjusted to ensure proper engagement and braking action.

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. To adjust clutch, tighten or loosen lock nuts on

flange studs (Fig. 33).

3. Check adjustment by inserting feeler gauge thru

slots next to studs.

4. The proper disengaged clearance between the

clutch plates is 0.30-0.45 mm (.012–.018 in.). It will be necessary to check this clearance at each of the three slots to ensure the plates are parallel to each other.

9. Reinstall belt gurard. See Installing Belt Guard

on page 21.

1. Lock

nut

Figure 33



Adjustment slot

Maintenance

Check

Hydraulic System Fluid

The hydraulic system is designed to operate on SAE 10W–30 engine oil or, as a substitute, SAE 10W–40 engine oil. The reservoir is filled at the factory with approximately 4.73l (5 U.S. quarts) of 10W–30 engine oil. Check reservoir oil level before engine is first started and daily thereafter.

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Position machine on a level surface and stop the

engine.

3. Remove dipstick cap from filler neck (Fig. 34)

and wipe it with a clean rag. Insert dipstick cap onto filler neck; then remove it and check level of oil.

4. If level is not within 1/2 inch from full mark on

dipstick, add SAE 10W–30 engine oil to raise level to FULL mark. Do not overfill.

5. Install dipstick filler cap onto filler neck

(Fig. 34).

6. Run engine for approximately 1 minute, recheck

reservoir oil level and add as required.

7. Reinstall belt gurard. See Installing Belt Guard

on page 21.

Change

Hydraulic System Oil

The hydraulic system oil must be changed after every 250 hours of operation or yearly, whichever comes first. The reservoir has a capacity of approximately

4.73l (5 U.S. quarts).

1. Park machine on a level surface, lower cutting unit, engage parking brake. and shut engine off.

2. Clean the area around the hydraulic oil filter and remove the filter from the bottom of the filter housing. use bottom type filter wrench (Fig. 35).

Disconnect tube assembly and hose assembly from reservoir and allow the oil to flow into a drain pan (Fig. 35).

Note: To drain oil remaining in system,

disconnect spark plug wires and crank engine for 15 seconds. This will pump remaining oil out of system thru tube assembly. Do not crank engine for more than 15 seconds.

4. Install the new hydraulic filter onto bottom of the filter housing (Fig. 35).

5. Install the tube assembly and hose assembly to reservoir (Fig. 35).

1. Dipstick

cap

Figure 34



1. Filter

2. Reservoir

Figure 35

3. Hose

4. T



assembly

ube assembly

Maintenance

6. Fill the reservoir to the proper level; refer to

Check Hydraulic System Fluid.

7. Place all controls in neutral or disengaged

position and start engine. Run engine at lowest possible RPM to purge the system of air.

8. Run engine until lift cylinder extends and

retracts and forward and reverse wheel motion is achieved.

9. Stop the engine and check the oil level in

reservoir, add oil if necessary.

10. Check all connections for leaks.

Change

Hydraulic Oil Filter

The hydraulic oil filter keeps the hydraulic system relatively free of contaminants. However, the hydraulic oil filter must be serviced at regular intervals. The intervals are: initially, after the first 5 hours of operation, and thereafter every 250 hours of operation or yearly, whichever comes first. Use a genuine TORO oil filter for replacement.

Adjust

Steering

1. Measure toe-in distance (at axle height) at front

and rear of steering tires. Front measurement must be 0–1/4 inch (6 mm) less than rear measurement.

2. Loosening jam nuts and rotating tie rod to adjust

clearance (Fig. 36).

3. Turn steering wheel full left to achieve a full left

turn (Fig. 36).

4. Check clearance between left tire and tie rod.

There should be 1 inch (25 mm) ± 1/4 inch (6 mm) clearance at this position.

5. Loosening jam nuts and rotating steering rod to

adjust clearance (Fig. 36).

6. Rotate tie rod to move front of tire in or out.

7. Tighten jam nuts when adjustment is correct.

1. Remove hydraulic oil filter from mounting head.

Use bottom type filter wrench (Fig. 35). Dispose of filter properly.

2. Apply a film of oil on the gasket. Install filter by

hand until gasket contacts mounting head; then tighten filter an additional 3/4 turn.

3. Start engine and check for oil leaks. Allow

engine to run for about 2 minutes so any air in system is pur

ged. Then shut engine off.

4. Check level of oil in reservoir; refer to Check

Hydraulic System Fluid, page 34.



1. Tie

rod

Figure 36

Steering rod

Maintenance

Hydraulic

Schematic

TRANSMISSION

VALVE

RESERVOIR

FILTER



CYLINDER

T-0084

1.9L 

4.73L (5QT.)

18.93L (5GAL.)

14.9cl (44oz)

Maintenance

Change

Front Axle Oil

After every 500 hours of operation, change oil in the front axle.

1. Run machine before changing oil to warm oil.

Warm oil flows more freely and carries more contaminants than cold oil.

2. Clean area around drain plug and place a drain

pan below drain plug on axle (Fig. 37).

3. Remove drain plug and allow oil to flow into

drain pan (Fig. 37). After oil is drained, reinstall drain plug.

4. Remove fill plug and fill to plug level with SAE

EP-90 wt. oil (approximately 14.9cl (44 oz.)) (Fig. 37).

Battery

Service Interval/Specification

Check the electrolyte level in the battery every 50 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Voltage: 12 v, 280 Cold Cranking Amps

Checking Electrolyte Level

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. With the engine off, open the covers to see into

the cells. The electrolyte must be up to the lower part of the tube (Fig. 38). Do not allow the electrolyte to get below the plates. (Fig. 38).

1. Drain

plug

Figure 37

Fill plug



3. If the electrolyte is low, add the required amount

of distilled water; refer to Adding Water to the Battery, page 38.

4. Reinstall belt gurard. See Installing Belt Guard

on page 21.

1. Filler

caps

Lower part of tube

Figure 38

3. Plates

1262

Maintenance

Adding Water to the Battery

The best time to add distilled water to the battery is just before you operate the machine. This lets the water mix thoroughly with the electrolyte solution.

POTENTIAL HAZARD

• Charging the battery pr

oduces gasses.

1. Clean the top of the battery with a paper towel.

2. Lift off the filler caps (Fig. 38).

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 38).

IMPORTANT: Do not overfill the battery because electr sever

e corr

4. Press the filler caps onto the battery.

olyte (sulfuric acid) can cause

osion and damage to the chassis.

Charging the Battery

IMPORTANT: Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F).

1. Raise seat and remove belt guard. See Removing

Belt Guard on page 21.

2. Remove the battery from the holder.

3. Check the electrolyte level; refer to Checking

Electrolyte Level.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

5. Install the battery into the holder.

6. Reinstall belt gurard. See Installing Belt Guard

on page 21.

Wire

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

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

Harness Service

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

4. Remove the filler caps from the battery and

connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts). Do not overcharge the battery. Install the filler caps after the battery is fully charged.

Maintenance

Wiring

CLUTCH

HOUR METER

O SWITCH CIRCUITR

ON OFF

A + B C + D

Diagram

DIODE MODULE

CONNECTOR

WHITE BLACK BLACK

PTO SWITCH

IGNITION

GREY

ENGINE CONNECTOR

N O

BLACK

BLUE

BROWN

ORANGE

N C

RELAY

Y AB

KEY SWITCH

GREEN

BLUE

VIOLET

SWITCH CIRCUITR

START

RUN OFF

B+S+I A+B+I

OPEN

X+Y

O MAGNET

O REGULA

TOR

O ST

ARTER



CLOSED WHEN TRACTION PEDAL IS IN NEUTRAL

NEUTRAL

ARKING BRAKE

CLOSED WHEN PARKING BRAKE IN OFF POSITION

SEAT

OPEN WHEN OPERATOR IS NOT IN SEAT

REDRED

FUSE

20 A

RED

STARTER

RED

BLACK

Maintenance

Cleaning

1. Disengage the power take off (PTO), set the

parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Remove grass clippings, dirt, and grime from the

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

IMPORTANT: You can wash the machine with mild detergent and water. Do not pressure wash the machine. A use of water, especially near the control panel, and engine.

3. Check the brake; refer to Brake, page 28.

4. Service the air cleaner; refer to Air Cleaner,

page NO TAG.

5. Grease the machine; refer to Greasing and

Lubrication, page 26.

6. Change the crankcase oil and filter; refer to

Engine Oil, page 23.

and Storage

void excessive

IMPORTANT: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 0° C (32° F). A fully charged battery maintains its charge for about 50 days at temperatures lower than 4° C (40° F). If temperatures will be above 4° C (40° F), check the electrolyte level in the battery and charge every 30 days.

9. Check the tire pressure; refer to Tire Pressure,

page 29.

10. During long-term storage, either drain gasoline from the fuel tank (step 11) or add a fuel stabilizer/conditioner additive to a full tank of gasoline (step A).

11. Drain gasoline from the fuel tank. After fuel is drained, start the engine and let it idle until all gasoline is consumed and the engine stops. This eliminates gum-like buildup in the fuel system, which causes hard starting. Try to start the engine two more times to assure that no gasoline is in the fuel system.

A. Add the correct amount of a fuel

stabilizer/conditioner to a full tank of gasoline.

7. Change the hydraulic system oil and filter; refer

to Change Hydraulic Oil and Filter, page 34.

8. Remove the battery from the chassis, check the

electrolyte level, and charge fully; refer to Battery, page 37. Do not connect the battery cables to the battery posts during storage.

Note: Stabilizer/conditioners normally

preserve gasoline for six to eight months.

12. Remove the spark plug(s) and check its

condition; refer to Spark Plug, page 25. 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).

13. Check and tighten all bolts, nuts, and screws.

Repair or replace any part that is damaged or defective.

14. Paint all scratched or bare metal surfaces. Paint

is available from your Authorized Service Dealer.

15. Store the machine in a clean, dry garage or

storage area. Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

Maintenance

Troubleshooting

g,,

PROBLEM

Starter does not rotate.

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

POSSIBLE CAUSES

Power take of is ENGAGED.

2. T

raction control pedal is not in

neutral.

Electrical connections are corroded or loose.

Fuse is blown.

Battery is dead.

Solenoid or switch is defective.

Operator is not seated.

Parking brake is OFF

Fuel tank is empty

Choke is not ON.

Air cleaner is dirty

Spark plug wire is loose or disconnected.

f (PT

O) switch

. 3.

. 5.

CORRECTIVE ACTION

Move (PT DISENGAGED.

Move traction control pedal to neutral position.

Check electrical connections for good contact.

Replace fuse. Charge battery

Contact Authorized Service Dealer.

Sit on seat. Move parking brake to ON.

Fill fuel tank with gasoline. Move choke lever to ON. Clean or replace air cleaner

element. Install wire on spark plug.

O) switch to

Engine loses power

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

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Air cleaner is dirty

Oil level in crankcase is low

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

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

6. V

ent hole in fuel cap is

plugged.

Dirt in fuel filter

Dirt, water fuel system.

. 8.

, or stale fuel is in

. 2.

. 7.

, or stale fuel is in

. 3.

Install new spark plug.

Replace fuel filter Contact Authorized Service

Dealer. Reduce ground speed. Clean air cleaner element. Add oil to crankcase. Remove obstruction from

cooling fins and air passages.

Install new spark plug.

Clean or replace the fuel cap.

Replace fuel filter Contact Authorized Service

Dealer.

, correctly gapped

Troubleshooting

PROBLEM

Engine overheats.

Abnormal vibration.

Machine does not drive.

POSSIBLE CAUSES

Engine load is excessive.

Oil level in crankcase is low

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

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

1. T

raction belt is worn, loose or

broken.

2. T

raction belt is of

f pulley

, idler

. 2.

1. T

2. T

CORRECTIVE ACTION

Reduce ground speed. Add oil to crankcase. Remove obstruction from

cooling fins and air passages.

ighten engine mounting

bolts.

ighten the appropriate

pulley. Contact Authorized Service

Dealer. Adjust belt tension, replace

belt. Contact Authorized Service

Dealer.

Toro 30611 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual