Toro 72523 Operator's Manual

Download

FormNo.3435-596RevA

GrandStand

MultiForceMower

With52inor60inTURBOFORCE Unit

ModelNo.72523—SerialNo.400000000andUp ModelNo.72529—SerialNo.400000000andUp

Cutting

Registeratwww.T oro.com. OriginalInstructions(EN)

*3435-596*A

ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

Theenclosedengineowner'smanualissupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCaliforniaEmission ControlRegulationofemissionsystems,maintenance, andwarranty.Replacementsmaybeorderedthrough theenginemanufacturer.

Pleaserefertotheenginemanufacturer’sinformation includedwiththemachine.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

Useofthisproductmaycauseexposure

tochemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Withyourmobiledevice,youcan

scantheQRcodeontheserialnumberdecal(if equipped)toaccesswarranty,parts,andother productinformation.

g235457

Figure1

1.Locationofthemodelandserialnumbers

ModelNo.

SerialNo.

Introduction

Thisrotary-blade,stand-onlawnmowerisintended tobeusedbyprofessional,hiredoperators.Itis designedprimarilyforcuttinggrassonwell-maintained lawnsonresidentialorcommercialproperties.Using thisproductforpurposesotherthanitsintendeduse couldprovedangeroustoyouandbystanders.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .

Visitwww.Toro.comformoreinformation,including safetytips,trainingmaterials,accessoryinformation, helpndingadealer,ortoregisteryourproduct.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Contactusatwww.Toro.com.

g000502

PrintedintheUSA

AllRightsReserved

Contents

Safety.......................................................................4

GeneralSafety...................................................4

SafetyandInstructionalDecals..........................4

ProductOverview.....................................................9

Controls.............................................................9

Specications...................................................11

Attachments/Accessories..................................11

BeforeOperation..................................................11

BeforeOperationSafety....................................11

AddingFuel......................................................12

PerformingDailyMaintenance..........................13

BreakinginaNewMachine..............................13

UsingtheSafety-InterlockSystem....................13

DuringOperation.................................................14

DuringOperationSafety...................................14

OperatingtheParkingBrake.............................15

OperatingthePower-T akeoff(PTO)

Switch...........................................................15

OperatingtheThrottle.......................................16

OperatingtheIgnitionSwitch............................16

StartingtheEngine...........................................17

ShuttingOfftheEngine.....................................17

OperatingthePlatform......................................18

DrivingForwardorBackward............................18

SideDischargingorMulchingthe

Grass............................................................20

AdjustingtheHeight-of-Cut...............................20

AdjustingtheAnti-ScalpRollers........................21

AdjustingtheFlowBafe..................................21

PositioningtheFlowBafe................................21

UsingWeights..................................................22

AfterOperation....................................................22

AfterOperationSafety......................................22

PreventingFreeze-upafterUse........................23

UsingtheFuel-ShutoffValve.............................23

PushingtheMachinebyHand..........................23

TransportingtheMachine.................................24

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

MaintenanceSafety..........................................26

RecommendedMaintenanceSchedule(s)...........26

Pre-MaintenanceProcedures..............................27

ReleasingtheCushionforRearAccess............27

Lubrication..........................................................28

GreasingtheMachine.......................................28

GreasingtheAccessoryFrame.........................28

GreasingtheT orsionIdler.................................28

GreasingtheFrontCasterPivots......................28

GreasingtheCaster-WheelHubs.....................29

GreasingtheEngineVoltageRegulator............29

GreasingtheBrakeCalipers.............................30

GreasingtheMotionControls...........................30

EngineMaintenance...........................................31

EngineSafety...................................................31

ServicingtheAirCleaner..................................31

ServicingtheEngineOil....................................32

ServicingtheSparkPlug...................................36

CheckingtheSparkArrester.............................37

FuelSystemMaintenance...................................37

DrainingtheFuelT ank......................................37

RemovingtheFuelT ank...................................38

ReplacingtheFuelFilter...................................38

ElectricalSystemMaintenance...........................39

ElectricalSystemSafety...................................39

ServicingtheBattery.........................................39

ServicingtheFuses..........................................41

DriveSystemMaintenance..................................41

AdjustingtheTracking......................................41

CheckingtheTirePressure...............................42

AdjustingtheCaster-PivotBearing...................42

ServicingtheCasterWheelsand

Bearings........................................................43

RemovingtheClutchShim...............................43

CheckingtheWheel-LugNuts..........................45

CoolingSystemMaintenance..............................45

CleaningtheAir-IntakeScreen.........................45

CleaningtheCoolingSystem............................45

BrakeMaintenance.............................................46

TestingtheParkingBrake.................................46

AdjustingtheBrakes.........................................46

BeltMaintenance................................................46

CheckingtheBelts............................................46

ReplacingtheMower-DeckBelt........................46

ReplacingtheTransmissionBelt......................47

ControlsSystemMaintenance.............................48

AdjustingtheMotion-ControlLevers.................48

HydraulicSystemMaintenance...........................49

HydraulicSystemSafety...................................49

HydraulicSystemSpecications.......................49

CheckingtheHydraulicFluid............................49

ReplacingtheHydraulicFluidand

Filters............................................................50

BleedingtheHydraulicSystem.........................51

MowerDeckMaintenance....................................51

BladeSafety.....................................................51

ServicingtheCuttingBlades.............................51

RemovingtheMowerDeck...............................53

InstallingtheMowerDeck.................................55

LevelingtheMowerDeck..................................55

AdjustingtheDeck-LiftSpring...........................57

ReplacingtheGrassDeector..........................58

Cleaning..............................................................58

CleaningundertheMowerDeck.......................58

DisposingofWaste...........................................58

Storage...................................................................59

StorageSafety..................................................59

CleaningandStorage.......................................59

Troubleshooting......................................................60

Schematics.............................................................62

Safety

Thismachinehasbeendesignedinaccordancewith ANSIB71.4-2017.

GeneralSafety

Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriouspersonalinjury.

•Readandunderstandthecontentsofthis

Operator’sManualbeforestartingtheengine.

•Donotputyourhandsorfeetnearmoving

componentsofthemachine.

•Donotoperatethemachinewithoutallguards

andothersafetyprotectivedevicesinplaceand functioningproperlyonthemachine.

•Keepclearofthedischargeopening.

SafetyandInstructionalDecals

•Keepbystandersandchildrenoutoftheoperating

area.Donotallowchildrentooperatethemachine. Allowonlypeoplewhoareresponsible,trained, familiarwiththeinstructions,andphysically capabletooperatethemachine.

•Stopthemachine,shutofftheengine,andremove

theignitionkeybeforeservicing,fueling,or uncloggingthemachine.

Improperlyusingormaintainingthismachinecan resultininjury .T oreducethepotentialforinjury, complywiththesesafetyinstructionsandalways payattentiontothesafety-alertsymbol meansCaution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.

,which

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

1.Explosionhazard6.Keepbystandersaway

2.Nore,opename,or smoking

3.Causticliquid/chemical burnhazard

4.Weareyeprotection.9.Flusheyesimmediately

5.ReadtheOperator's Manual.

fromthebattery .

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

10.Containslead;donot discard

decaloemmarkt

Manufacturer'sMark

1.Thismarkindicatesthatthebladeisidentiedasapart fromtheoriginalmachinemanufacturer.

decalbatterysymbols

decal106-5517

106-5517

1.Warning—donottouchthehotsurface.

Decal112-3858isfor60inmachinesonly.

112-3858

decal112-3858

1.ReadtheOperator's Manual.

2.ReadtheOperator's

3.Removethekeybefore adjustingtheheightofcut.

4.Height-of-cutsettings

Manualbeforeperforming maintenance.

116-8283

1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto75to81N∙m(55to60ft-lb).

decal131-1180

131-1180

1.ReadtheOperator's Manual.

2.Short,lightgrass;dry conditions

decal116-8283

3.Baggingsetting

4.Tall,densegrass;wet conditions

1.ReadtheOperator’s

Manual.

116-8775

2.Warning—lltothebottom ofthellerneck;donot overllthetank.

decal131-3507

decal116-8775

1.ReadtheOperator's

131-3507

2.Belttensioner

Manual.

decal131-3521

131-3528

15A 15A 10A

7.5A

131-3521

1.Heightofcut

1.ReadtheOperator's Manual.

2.Transmissionuid

131-3524

3.Colduidlevel

decal131-3536

131-3536

1.Battery4.Parkingbrake

2.Time5.Engine—start

3.Powertakeoff(PTO)

6.Engagethehandlebars.

decal133-4604

133-4604

1.Thrownobject hazard—keepbystanders

decal131-3524

awayfromthemachine.

2.Thrownobjecthazard, openbafe—onlyoperate themachinewithabafe oragrasscollector.

3.Severinghazardofhand orfoot—keepawayfrom movingparts.

4.Entanglement hazard—keepaway frommovingparts;keep allguardsandshieldsin place.

1.Keyswitch—15A

2.Accessoryport—15A

131-3528

decal131-3528

3.Powertakeoff(PTO)—10 A

4.Infocenter—7.5A

133-4648

1.ReadtheOperator'sManualformoreinformationon servicingthemachine.

decal133-8062

133-8062

decal133-4648

decal131-3526

131-3526

1.Powertakeoff(PTO)—disengaged

2.Fast6.Tractiondrive

3.Slow

4.Neutral

5.Reverse

7.Engagethehandles.

decal139-2878

139-2878

1.Warning—readtheOperator’sManual.

2.Warning—alloperatorsshouldbetrainedbeforeoperating themachine.

3.Warning—wearhearingprotection.8.Tippinghazard—donotusedualrampswhenloadingontoa

4.Thrownobjecthazard—lowerthedeectorbeforeoperating themachine.

5.Cutting/dismembermenthazardofhandorfoot—stayaway frommovingparts;keepallguardsandshieldsinplace.

6.Thrownobjecthazard—keepbystandersaway .

7.Warning—engagetheparkingbrake,shutofftheengine,and removethekeybeforeleavingthemachineorperforming maintenance.

trailer;use1rampwideenoughforthemachine;backup therampwhenloadingthemachineanddriveforwardoffthe rampwhenunloading.

9.Tippinghazard—donotusethemachineneardrop-offsor onslopes;stayatleast2widthsofthemachineawayfrom drop-offs.

140-4260

1.Parkingbrake—disengaged5.Fast

2.Parkingbrake—engaged6.Enginespeed

3.On7.Slow

4.Off

decal140-4260

ProductOverview

Figure3

1.Adjustablecaster9.Motion-controllevers

2.Accessory-framelock

3.Anti-scalproller(60-inch decksonly)

4.Frontcasterwheel

5.Side-dischargechute13.Fuel-shutoffvalve

6.Accessoryframe

7.Engine15.Mowerdeck

8.Controlpanel

10.Hydraulictank

11.Fueltank

12.Platform(downposition)

14.Battery

Controls

Becomefamiliarwithallthecontrolsbeforeyoustart theengineandoperatethemachine(Figure4).

ControlPanel

g306613

g301785

Figure4

1.Fuelcap7.Keyswitch

2.Malfunction-indicatorlight (MIL)

3.Parking-brakelever

4.Hydraulic-tankcap

5.Hourmeter11.Motion-controllever

6.Power-takeoffswitch (PTO)

8.Throttlecontrol

9.Height-of-cutlever

10.Height-of-cutpin

12.Referencebar

Electronic-ControlUnit Malfunction-IndicatorLight

Theelectronic-controlunit(ECU)continuously monitorstheoperationoftheEFIsystem.

Ifaproblemorfaultwithinthesystemisdetected,the malfunction-indicatorlight(MIL)isilluminated(Figure

4).

TheMIListheredlightlocatedintheconsolepanel.

WhentheMILilluminates,makeinitialtroubleshooting checks;refertoTroubleshooting(page60).

Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedService Dealerisnecessary.

Power-TakeoffSwitch(PTO)

Usethepower-takeoffswitch(PTO)toengageand disengagemowerbladesorstartandstoppowered attachments(Figure4);refertoOperatingthe

Power-Takeoff(PTO)Switch(page15).

HourMeter

Fuel-ShutoffValve

Thehourmeterrecordsthenumberofhoursthe enginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance(Figure5).

Figure5

1.Safety-interlocksymbols

2.Batterylight

3.Hourmeter

Safety-InterlockIndicators

Symbolsonthehourmeterindicatewithablack trianglethattheinterlockcomponentisinthecorrect position(Figure5).

Closethefuel-shutoffvalvewhentransportingor storingthemachine;refertoUsingtheFuel-Shutoff

Valve(page23).

AccessoryFrame

UsetheaccessoryframetoattachonlyToro-approved accessoriestothemachine(Figure3).Refertothe Operator’sManualfortheaccessoryforinstallation instructions.

Accessory-FrameLock

Theaccessory-framelockholdstheframeinplaceon

g216020

themachineusingthelockpin.Alwayslocktheframe unlessahydraulickitisinstalledwithanaccessory onthemachine(Figure3).

AdjustableCasters

Whenusingthemachinewithoutanaccessory,place theadjustablecastersinthemowingposition(front hole)asshowninFigure6.Whenusingthemachine withanaccessory,refertotheOperator’sManualfor thataccessoryforthecorrectcasterposition.

Battery-IndicatorLight

IfyouturnthekeytotheONpositionforafew seconds,thebatteryvoltagedisplaysinthearea wherethehoursarenormallydisplayed.

Thebatterylightturnsonwhenyouturnthekeytothe ONpositionandwhenthechargeisbelowthecorrect operatinglevel(Figure5).

ThrottleControl

Thethrottlecontrolstheenginespeed,andithasa continuous-variablesettingfromtheSLOWtoFAST position(Figure4).

KeySwitch

Thekeyswitch,usedtostartandshutofftheengine, has3positions:OFF,RUN,andSTART.Referto

OperatingtheIgnitionSwitch(page16).

Motion-ControlLevers

g033081

Figure6

RightCasterShown

1.Mowingposition2.Accessorypositions

Usethemotion-controlleverstodrivethemachine forward,reverse,andturneitherdirection(Figure4).

Specications

Note:Specicationsanddesignaresubjectto

changewithoutnotice.

52inMowerDeck60inMowerDeck

Cuttingwidth131cm(52inches)152cm(60inches)

Widthwith deectordown

Widthwith deectorraised

Lengthwith platformdown

Lengthwith platformup

Height

Weight

173cm(68inches)193cm(76inches)

137cm(54inches)157cm(62inches)

191cm(75inches)201cm(79inches)

155cm(61inches)165cm(65inches)

122cm(48inches)122cm(48inches)

405kg(893lb)420kg(926lb)

Operation

BeforeOperation

BeforeOperationSafety

GeneralSafety

•Neverallowchildrenoruntrainedpeopletooperate

themachine.Localregulationsmayrestrictthe ageoftheoperator.Theownerisresponsiblefor trainingalloperatorsandmechanics.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Knowhowtostopthemachineandshutoffthe

enginequickly.

Attachments/Accessories

AselectionofT oroapprovedattachmentsand accessoriesisavailableforusewiththemachine toenhanceandexpanditscapabilities.Contact yourAuthorizedServiceDealerorauthorizedT oro distributororgotowww.Toro.comforalistofall approvedattachmentsandaccessories.

Toensureoptimumperformanceandcontinuedsafety certicationofthemachine,useonlygenuineT oro replacementpartsandaccessories.Replacement partsandaccessoriesmadebyothermanufacturers couldbedangerous,andsuchusecouldvoidthe productwarranty.

•Checkthatoperator-presencecontrols,safety

switches,andguardsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.

•Beforemowing,alwaysinspectthemachineto

ensurethattheblades,bladebolts,andcutting assembliesareingoodworkingcondition.

•Inspecttheareawhereyouwillusethemachine

andremoveallobjectsthatthemachinecould throw.

•Evaluatetheterraintodeterminetheappropriate

equipmentandanyattachmentsoraccessories requiredtooperatethemachineproperlyand safely.

FuelSafety

•Fuelisextremelyammableandhighlyexplosive.

Areorexplosionfromfuelcanburnyouand othersandcandamageproperty.

–Topreventastaticchargefromignitingthefuel,

placethecontainerand/ormachinedirectlyon thegroundbeforelling,notinavehicleoron anobject.

–Fillthefueltankoutdoors,inanopenarea,

whentheengineiscold.Wipeupanyfuelthat spills.

–Donothandlefuelwhensmokingoraroundan

openameorsparks.

–Donotremovethefuelcaporaddfueltothe

tankwhiletheengineisrunningorhot.

–Ifyouspillfuel,donotattempttostartthe

engine.Avoidcreatingasourceofignitionuntil thefuelvaporshavedissipated.

–Storefuelinanapprovedcontainerandkeep

itoutofthereachofchildren.

•Fuelisharmfulorfatalifswallowed.Long-term

exposuretovaporscancauseseriousinjuryand illness.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessyouuseafuel stabilizer.

•Donotaddoiltogasoline.

–Avoidprolongedbreathingofvapors.

–Keepyourhandsandfaceawayfromthe

nozzleandthefuel-tankopening.

–Keepfuelawayfromyoureyesandskin.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

•Donotllcontainersinsideavehicleoronatruck

ortrailerbedwithaplasticliner.Alwaysplace containersontheground,awayfromyourvehicle beforelling.

•Removetheequipmentfromthetruckortrailer

andrefuelitwhileitisontheground.Ifthisisnot possible,thenrefuelfromaportablecontainer ratherthanafuel-dispensernozzle.

•Donotoperatethemachinewithouttheentire

exhaustsysteminplaceandinproperworking condition.

•Keepthefuel-dispensernozzleincontactwith

therimofthefueltankorcontaineropeningat alltimesuntilfuelingiscomplete.Donotusea nozzlelock-opendevice.

•Ifyouspillfuelonyourclothing,changeyour

clothingimmediately.Wipeupanyfuelthatspills.

•Neveroverllthefueltank.Replacethefuelcap

andtightenitsecurely.

UsingStabilizer/Conditioner

Usefuelstabilizer/conditionerinthemachinetokeep thefuelfreshlongerwhenusedasdirectedbythe fuel-stabilizermanufacturer.

Important:Donotusefueladditivescontaining

methanolorethanol.

Addtheamountoffuelstabilizer/conditionertofresh fuelasdirectedbythefuel-stabilizermanufacturer.

FillingtheFuelTank

1.Parkthemachineonalevelsurface,disengage

thePTO,movethemotion-controlleverstothe NEUTRAL-LOCKposition,andengagetheparking brake.

2.Shutofftheengine,removethekey ,andwait

forallmovingpartstostopbeforeleavingthe operatingposition.

3.Cleanaroundthefuel-tankcapandremovethe

cap.

4.Fillthefueltanktothebottomofthellerneck.

Note:Donotllthefueltankcompletelyfull.

Theemptyspaceinthetankallowsthefuelto expand.

5.Installthefuel-tankcapsecurely.Wipeupany

spilledfuel.

AddingFuel

RecommendedFuel

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse.

Neverusegasolinethatcontainsmorethan 10%ethanolbyvolume,suchasE15(contains

15%ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.

•Donotusegasolinecontainingmethanol.

g038312

Figure7

PerformingDaily Maintenance

Beforestartingthemachineeachday ,performthe EachUse/DailyprocedureslistedinMaintenance

(page26).

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhen new,placingadditionalloadontheengine.Allow 40to50hoursofbreak-intimefornewmachinesto developfullpowerandbestperformance.

UsingtheSafety-Interlock System

WARNING

Ifsafety-interlockswitchesaredisconnected ordamaged,themachinecouldoperate unexpectedly,causingpersonalinjury .

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlock switchesdaily,andreplaceanydamaged switchesbeforeoperatingthemachine.

Understandingthe Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtoprevent PTOfromengagingunlessyoudo1ofthefollowing:

•Moveeithermotion-controllevertothecenter,

unlockedposition.

•PresstheONpositiononthePTOswitch.

Thesafety-interlocksystemisdesignedtostop theblades/attachmentifyoumoveorrelease bothmotion-controlleversintotheNEUTRAL-LOCK position.

Thehourmeterhassymbolstonotifytheuser wheneachinterlockcomponentisinthecorrect position.Whenthecomponentisinthecorrect position,atrianglelightsupinthecorresponding square(Figure8).

g031282

Figure8

1.Thetriangleslightupwhentheinterlockcomponentsare inthecorrectposition.

TestingtheSafety-Interlock System

ServiceInterval:Beforeeachuseordaily

Testthesafety-interlocksystembeforeyouusethe machineeachtime.

Note:Ifthesafetysystemdoesnotoperateas

describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately.

1.Starttheengine;refertoStartingtheEngine

(page17).

2.Movethemotion-controlleverstothecenter,

unlockedposition.

Note:Theblades/attachmentshouldstopand

theengineshouldstoprunning.

3.Starttheengineanddisengagetheparking

brake.

4.Moveeithermotion-controllevertothecenter,

unlockedposition.

5.Continueholdingthemotion-controlleverin

thecenter,unlockedpositionandpresstheON positiononthePTOswitch.

Note:Theclutchandblades/attachmentshould

engage.

6.Moveorreleasethemotion-controlleversinto

theNEUTRAL-LOCKposition.

Note:Theblades/attachmentshouldstopand

theengineshouldcontinuetorun.

7.PresstheOFFpositiononthePTOswitchand

moveeithermotion-controllevertothecenter, unlockedposition.

8.Continueholdingthemotion-controlleverin

thecenter,unlockedpositionandpresstheON positiononthePTOswitch.

Note:Theclutchandblades/attachmentshould

engage.

9.PresstheOFFpositiononthePTOswitch.

Note:Theblades/attachmentshouldstop.

10.Withtheenginerunning,presstheONposition onthePTOswitchwithoutholdingeither motion-controllevertothecenter,unlocked position.

Note:Theblades/attachmentshouldnot

engage.

DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible

foraccidentsthatmaycausepersonalinjuryor propertydamage.

•Wearappropriateclothing,includingeye

protection;longpants;substantial,slip-resistant footwear;andhearingprotection.Tiebacklong hairanddonotwearlooseclothingorloose jewelry.

•Useyourfullattentionwhileoperatingthe

machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Nevercarrypassengersonthemachineandkeep

bystandersandpetsawayfromthemachine duringoperation.

•Operatethemachineonlyingoodvisibilityand

appropriateweatherconditions.Donotoperate themachinewhenthereistheriskoflightning.

•Wetgrassorleavescancauseseriousinjuryif

youslipandcontacttheblade.Avoidmowingin wetconditions.

•Beforeyoustarttheengine,ensurethatalldrives

areinneutral,theparkingbrakeisengaged,and youareintheoperatingposition.

•Ensurethatyouhavegoodfootingwhileusingthis

machine,especiallywhenbackingup.

•Keepyourhandsandfeetawayfromthecutting

units.Keepclearofthedischargeopeningatall times.

•Lookbehindanddownbeforebackinguptobe

sureofaclearpath.

•Useextremecarewhenapproachingblind

corners,shrubs,trees,orotherobjectsthatmay blockyourview.

•Stopthebladeswheneveryouarenotmowing.

•Stopthemachine,removetheignitionkey,and

waitforallmovingpartstostopbeforeinspecting themowerdeckorattachmentafterstrikingan objectorifthereisanabnormalvibrationinthe machine.Makeallnecessaryrepairsbefore resumingoperation.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalkswiththe machine.Alwaysyieldtheright-of-way.

•Disengagethecuttingunitandshutofftheengine

beforeadjustingtheheightofcut(unlessyoucan adjustitfromtheoperatingposition).

•Operatetheengineonlyinwell-ventilatedareas.

Exhaustgasescontaincarbonmonoxide,which islethalifinhaled.

•Neverleavearunningmachineunattended.

•Beforeleavingtheoperatingposition(including

toemptythecatchersortounclogthechute),do thefollowing:

–Parkthemachineonalevelsurface.

–Disengagethepowertake-off.

–Engagetheparkingbrake.

–Shutofftheengineandremovetheignitionkey.

–Waitforallmovingpartstostop.

•Shutoffthemachineanddisengagethedriveto

thecuttingunitinthefollowingsituations:

–Beforefueling

–Beforeclearingblockages

–Beforechecking,cleaning,ormaintainingthe

cuttingunit

–Afterstrikingaforeignobjectorifanabnormal

vibrationoccurs.Inspectthecuttingunitfor damageandmakerepairsbeforestartingand operatingthemachine

–Beforeleavingtheoperatingposition

•Donotusethemachineasatowingvehicle.

•Useonlyaccessoriesandattachmentsapproved

byTheT oro®Company.

SlopeSafety

•Slopesareamajorfactorrelatedtolossofcontrol

androlloveraccidents,whichcanresultinsevere injuryordeath.Youareresponsibleforsafeslope operation.Operatingthemachineonanyslope requiresextracaution.Beforeusingthemachine onaslope,dothefollowing:

–Reviewandunderstandtheslopeinstructions

inthemanualandonthemachine.

–Evaluatethesiteconditionsofthedayto

determineiftheslopeissafeformachine

operation.Usecommonsenseandgood judgmentwhenperformingthisevaluation. Changesintheterrain,suchasmoisture,can quicklyaffecttheoperationofthemachineon aslope.

•Operateacrossslopes,neverupanddown.Avoid

operationonexcessivelysteeporwetslopes.

•Identifyhazardsatthebaseoftheslope.Do

notoperatethemachineneardrop-offs,ditches, embankments,water,orotherhazards.The machinecouldsuddenlyrolloverifawheelgoes overtheedgeortheedgecollapses.Keepasafe distance(twicethewidthofthemachine)between themachineandanyhazard.Useawalk-behind machineorahandheldtooltooperateinthese areas.

•Avoidstarting,stopping,orturningthemachineon

slopes.Avoidmakingsuddenchangesinspeedor direction;turnslowlyandgradually.

•Donotoperateamachineunderanyconditions

wheretraction,steeringorstabilityisinquestion. Beawarethatoperatingthemachineonwet grass,acrossslopesordownhillmaycausethe machinetolosetraction.Lossoftractiontothe drivewheelsmayresultinslidingandalossof brakingandsteering.Themachinecanslideeven ifthedrivewheelsarestopped.

•Removeormarkobstaclessuchasditches,holes,

ruts,bumps,rocks,orotherhiddenhazards.T all grasscanhideobstacles.Uneventerraincould overturnthemachine.

g009465

Figure9

1.Parkingbrake—engaged2.Parking brake—disengaged

Operatingthe Power-Takeoff(PTO) Switch

Usethepower-takeoff(PTO)switchinconjunctionwith themotion-controlleverstoengageanddisengage themowerbladesorpowerattachments.

EngagingthePower-Takeoff(PTO) Switch

•Useextracarewhileoperatingwithaccessoriesor

attachments.Thesecanchangethestabilityof themachineandcausealossofcontrol.Follow directionsforcounterweights.

•Ifyoulosecontrolofthemachine,stepoffand

awayfromthedirectionoftravelofthemachine.

OperatingtheParking Brake

Alwaysengagetheparkingbrakewhenyoushutoff themachineorleaveitunattended.Beforeeachuse, checktheparkingbrakeforproperoperation.

Iftheparkingbrakedoesnotholdsecurely,adjustit; refertoAdjustingtheBrakes(page46).

Pulltheparking-brakeleverrearwardtoengageit (Figure9).

Pushtheparking-brakeleverforwardtodisengageit.

g301277

Figure10

DisengagingthePower-Takeoff (PTO)Switch

Figure11andFigure12show2waystodisengage

thePTO.

Figure11

Figure12

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweenFASTand SLOWpositions(Figure13).

AlwaysusetheFASTpositionwhenengagingthePTO.

g008946

Figure13

g301401

OperatingtheIgnition Switch

Important:Donotengagethestarterformore

than5secondsatatime.Iftheenginefailsto start,wait15secondsbetweenattempts.Failure

g031593

tofollowtheseinstructionscanburnoutthe startermotor.

Note:IfyoudisengagethePTObyreleasingthe

motion-controllevers,youcanengagethePTOagain bypressingtheONpositionoftheswitchwithout pressingtheOFFpositionrst.

Note:Y oumayneedtorepeatthecycleforstarting

theenginewhenyoustartitforthersttimeafteryou havelledacompletelyemptyfuelsystemwithfuel.

g031239

Figure14

g031281

Figure15

StartingtheEngine

Important:Donotengagethestarterformore

than5secondsatatime.Iftheenginefailsto start,wait15secondsbetweenattempts.Failure tofollowtheseinstructionscanburnoutthe startermotor.

Note:Y oumayneedtorepeatthecycleforstarting

theenginewhenyoustartitforthersttimeafteryou havelledacompletelyemptyfuelsystemwithfuel.

Note:Themachinemayhavedifcultystartingunder

severecoldconditions.Whenstartingacoldmachine, keepthemachineabove-23°C(-10°F).

ShuttingOfftheEngine

CAUTION

Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.

Alwaysremovethekeyandengagethe parkingbrakewhenleavingthemachine unattended.

Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningthekeyswitchtotheOFF position.

Important:Startingandshuttingofftheengine

frequentlyincoldconditionscandamagethe engine.Allowthemachinetoreachnormal operatingtemperaturebeforeshuttingoffthe engine.

Figure16

g306776

g301288

Figure17

Important:Makesurethatthefuel-shutoffvalve

isclosedbeforetransportingorstoringthe machinetopreventafuelleak.Beforestoringthe machine,disconnectthesparkplug(s)toprevent thepossibilityofaccidentalstarting.

OperatingthePlatform

Youcanusethemachinewiththeplatforminthe upordownposition.Itisyourpreferenceonwhich positiontouse.

WARNING

Theoperatorplatformisheavyandmaycause injurywhenyouraiseorlowerit.Carefully lowerorraisetheoperatorplatform,as suddenlydroppingitcouldinjureyou.

•Donotputyourhandsorngersinthe platform-pivotareawhenloweringor raisingtheoperatorplatform.

•Makesurethattheplatformissupported whenyoupullthelatchpinout.

•Makesurethatthelatchsecuresthe platformwhenfoldingitup.Pushittight againstthecushionforthelatchpinto lockintoplace.

•Keepbystandersawayfromthemachine whenraisingorloweringtheplatform.

1.Platformup

2.Platformdown

g031026

Figure18

3.Pulltheknobouttorelease theplatform.

OperatingtheMachinewiththe PlatformUp

Operatethemachinewiththeplatformupforthe followingconditions:

•Usingthemachineneardrop-offs

•Usingthemachineinsmallareaswherethe

machineistoolarge

•Areaswithlow-hangingbranchesorobstacles

•Loadingthemachinefortransport

•Drivingupslopes

Toraisetheplatform,pullthebackoftheplatformup sothatthelatchpinandknoblockitintoplace.Push ittightagainstthecushionforthelatchpintolockit intoplace.

OperatingtheMachinewiththe PlatformDown

Operatethemachinewiththeplatformdownforthe followingconditions:

•Usingthemachineinmostareas

•Drivingacrossslopes

•Drivingdownslopes

DrivingForwardor Backward

Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolintheFASTpositionforbest performance.

Important:Backthemachineovercurbs,1wheel

atatime;drivingitforwardovercurbscould damagethemachine.

CAUTION

Themachinecanspinveryrapidly,andyou maylosecontrolofthemachine,causing personalinjurytoyouanddamagetothe machine.

Slowdownthemachinebeforemakingsharp turns.

Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatch pin,thenpulltheknoboutandlowertheplatform (Figure18).

DrivingForward

1.Disengagetheparkingbrake;refertoOperating

theParkingBrake(page15).

2.Movethemotion-controlleverstothecenter, unlockedposition.

g009473

Figure20

Figure19

1.Frontreferencebar

2.Leftcontrollever

3.Rearreferencebar6.Leftcontrolleverinthe

4.Rightcontrollever

5.Rightcontrolleverinthe NEUTRAL-LOCKposition

NEUTRAL-LOCKposition

3.Slowlypushthemotion-controlleversforward (Figure20).

Note:Theengineshutsoffifyoumovea

motion-controlleverwhiletheparkingbrakeis engaged.

Note:Thefartheryoumovethemotion-control

leversineitherdirection,thefasterthemachine movesinthatdirection.

Note:T ostop,pullthemotion-controllevers

backtotheNEUTRALposition.

g030983

DrivingBackward

1.Movebothmotion-controlleverstothecenter, unlockedposition.

2.Slowlypullthemotion-controlleversrearward (Figure21).

g009474

Figure21

SideDischargingor

AdjustingtheHeight-of-Cut

MulchingtheGrass

Thismachinehasahingedgrassdeectorthat dispersesclippingstothesideanddowntowardthe turf.

DANGER

Withoutthegrassdeector,dischargecover, orcompletegrasscatcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris causeinjuryordeath.

•Donotremovethegrassdeectorfrom themachine,becausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.

•Neverputyourhandsorfeetunderthe machine.

•Nevertrytoclearthedischargeareaor mowerbladesunlessyoureleasethebail andthepowertakeoff(PTO)isoff.Rotate thekeytotheOFFposition.Alsoremove thekeyanddisconnectthewire(s)from thesparkplug(s).

Theheight-of-cutcanbeadjustedfrom38to127mm (1-1/2to5inches)in6mm(1/4inch)increments.

Note:Usingaheight-of-cutunder51mm(2inches)

increasesthewearonthemower-deckbelt.Usea height-of-cutthatisgreaterthan51mm(2inches) wheneverpossible.

g267253

Figure22

AdjustingtheAnti-Scalp Rollers

Modelswitha60-InchDeckOnly

Wheneveryouchangetheheight-of-cut,adjustthe heightoftheanti-scalprollers.

1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethenutandboltpositiontheanti-scalp rollersandinstallthenutandbolt.

4.Ensurethatthespacersandbushingsare installed(Figure23).

Figure24

1.Slot

2.Knob

PositioningtheFlowBafe

Thefollowingguresareforrecommendeduseonly. Adjustmentsvarybygrasstype,moisturecontent, andtheheightofthegrass.

g301806

Figure23

1.Bushing4.Bolt

2.Anti-scalproller5.Nut

3.Spacer

AdjustingtheFlowBafe

Youcanadjustthemower-dischargeowfordifferent typesofmowingconditions.Positionthecamlock andbafetoprovidethebestqualityofcut.

1.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Toadjustthebafe,loosentheknob(Figure24).

4.Adjustthebafeandknobintheslottothe desireddischargeowandtightentheknob.

Note:Iftheenginepowerdrawsdownandthe

mowergroundspeedisthesame,openthebafe.

PositionA

Thisisthefull,rearposition(seeFigure25).Usethis positionforthefollowing:

•Inshort,lightgrassmowingconditions

g018324

•Indryconditions

•Smallergrassclippings

•Propelsgrassclippingsfartherawayfromthe

mower

g012677

Figure25

PositionB

UsingWeights

Usethispositionwhenbagging(Figure26).

Figure26

PositionC

Thisisthefull,openposition(Figure27).Usethis positionforthefollowing:

•Installweightstoimprovebalance.Youcanaddor

removeweightstocreateoptimizedperformance underdifferentoperatingconditionsandforyour preference.

•Addorremoveweights1atatimeuntilyou

achievethedesiredhandlingandbalance.

•RefertotheOperator’sManualofattachmentsfor

recommendedweights.

Note:ContactanAuthorizedServiceDealertoorder

aweightkit.

WARNING

Excessiveweightchangescanaffectthe handlingandoperationofthemachine.

g012678

Thiscouldcauseseriousinjurytoyouor bystanders.

•Makeweightchangesinsmallincrements only.

•Evaluatethemachineaftereachweight changetoensurethatyoucanoperatethe machinesafely.

•Intall,densegrassmowingconditions

•Inwetconditions

•Lowerstheengine-powerconsumption

•Allowsincreasedgroundspeedinheavyconditions

Figure27

AfterOperation

AfterOperationSafety

GeneralSafety

•Alwaysshutoffthemachine,removetheignition

key,waitforallmovingpartstostop,andallow themachinetocoolbeforeadjusting,servicing, cleaning,orstoringit.

•Cleangrassanddebrisfromthecuttingunits,

mufers,andenginecompartmenttohelpprevent res.Cleanupoilorfuelspills.

•Shutoffthefuelbeforestoringortransportingthe

machine.

•DisengagethePTOwheneveryouaretransporting

ornotusingthemachine.

g012679

•Neverstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

•Usefull-widthrampsforloadingthemachineinto

atrailerortruck.

•Tiethemachinedownsecurelyusingstraps,

chains,cable,orropes.Bothfrontandrearstraps shouldbedirecteddownandoutwardfromthe machine.

PreventingFreeze-upafter

PushingtheMachineby

Use

•Insnowyandcoldconditions,somecontrolsand

movingpartsmayfreeze.Donotuseexcessive

forcewhentryingtooperatefrozencontrols.

Ifyouhavedifcultyoperatinganycontrolorpart, starttheengineandletitrunforafewminutes. Thawfrozenpartsbeforeoperatingthemachine.

•Afterusingthemachine,lettheenginerunfora

fewminutestopreventmovingpartsfromfreezing. Shutofftheengine,waitforallmovingparts tostop,andremovealliceandsnowfromthe machine.

UsingtheFuel-Shutoff Valve

Closethefuel-shutoffvalvefortransport,maintenance, andstorage(Figure28).

Ensurethatthefuel-shutoffvalveisopenwhen startingtheengine.

Hand

Thebypassvalvesallowyoutopushthemachineby handwithouttheenginerunning.

Important:Alwayspushthemachinebyhand.

Donottowthemachine,becausehydraulic damagemayoccur.

Important:Donotstartoroperatethemachine

withthebypassvalvesopen.Damagetosystem mayoccur.

Figure28

1.ONposition2.OFFposition

g032688

g031238

Figure29

g306777

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe machine.Useafull-widthramp.Ensurethatthetrailer ortruckhasallthenecessarybrakes,lighting,and markingasrequiredbylaw.Pleasecarefullyreadall thesafetyinstructions.Knowingthisinformationcould helpyouorbystandersavoidinjury.Refertoyour localordinancesfortrailerandtie-downrequirements.

WARNING

Drivingonthestreetorroadwaywithout turnsignals,lights,reectivemarkings,ora slow-moving-vehicleemblemisdangerous andcanleadtoaccidents,causingpersonal injury.

Donotdrivethemachineonapublicstreet orroadway.

SelectingaTrailer

WARNING

Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath(Figure30).

•Useonlyafull-widthramp;donotuse individualrampsforeachsideofthe machine.

•Ensurethatthelengthoframpisatleast4 timesaslongastheheightofthetraileror truckbedtotheground.

Figure30

1.Full-widthrampinstowed position

2.Rampisatleast4times aslongastheheightof thetrailerortruckbedto theground

3.H=heightofthetraileror truckbedtotheground

4.Trailer

LoadingtheMachine

WARNING

Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath.

•Useextremecautionwhenoperatinga machineonaramp.

•Backthemachineuptherampandwalkit forwarddowntheramp.

g229507

•Avoidsuddenaccelerationordeceleration whiledrivingthemachineonarampas thiscouldcausealossofcontrolora tip-oversituation.

1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.

2.Ifapplicable,connectthetrailerbrakesand lights.

3.Lowertheramp(Figure30).

4.Raisetheplatform.

Important:Alwayskeeptheplatformup

whenloadingandunloadingthemachine.

5.Backthemachineuptheramp(Figure31).

Figure31

g031405

1.Backthemachineupthe ramp.

2.Walkthemachinedown theramp.

6.Shutofftheengine,removethekey,andengage theparkingbrake.

7.Tiedownthemachinenearthefrontcaster wheelsandtherearbumperwithstraps,chains, cable,orropes(Figure32).Refertolocal regulationsfortie-downrequirements.

Figure32

1.Tie-downloops

g032703

Maintenance

Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.

CAUTION

Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.

Removethekeyfromtheignitionanddisconnectthespark-plugwiresfromthesparkplugs beforeyoudoanymaintenance.Setthewiresasidesothattheydonotaccidentallycontact thesparkplugs.

MaintenanceSafety

•Beforeadjusting,cleaning,servicing,orleaving

themachine,dothefollowing:

–Parkthemachineonalevelsurface.

–Disengagethedrives.

–Engagetheparkingbrake.

–Shutofftheengineandremovetheignitionkey.

–Waitforallmovingpartstostop.

–Allowmachinecomponentstocoolbefore

performingmaintenance.

•Donotallowuntrainedpersonneltoservicethe

machine.

•Keepyourhandsandfeetawayfrommoving

parts.Ifpossible,donotmakeadjustmentswith theenginerunning.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Checktheparkingbrakeoperationfrequently.

Adjustandservicethebrakeasneeded.

•Nevertamperwithsafetydevices.Checktheir

properoperationregularly.

•Cleangrassanddebrisfromthecuttingunit,

drives,mufer,andenginetohelppreventres. Cleanupoilorfuelspills.

•Checkthegrasscatchercomponentsfrequently

andreplacethemwhentheyarewornordamaged.

•Donotrelyonahydraulicsystemtosupportthe

machine;supportthemachinewithjackstands wheneveryouraisethemachine.

•Keepallpartsingoodworkingconditionandall

hydraulicttingstight.Replaceallworn,damaged, ormissingpartsanddecals.Keepallfasteners tighttoensurethatthemachineisinsafeworking condition.

•Toensureoptimumperformanceandcontinued

safetycerticationofthemachine,useonly genuineT ororeplacementpartsandaccessories. Replacementpartsandaccessoriesmadeby othermanufacturerscouldbedangerous,and suchusecouldvoidtheproductwarranty.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst8hours

Aftertherst50hours

Aftertherst100hours

Beforeeachuseordaily

Every50hours

MaintenanceProcedure

•Changetheengineoil.

•Checkthehydraulic-uidlevel.

•Changethehydraulicltersandhydraulicuid.

•Checkthewheel-lugnuts.

•Checkthesafety-interlocksystem.

•Checktheengine-oillevel.

•Cleantheair-intakescreen(moreoftenindirtyordustyconditions).

•Testtheparkingbrake.

•Inspecttheblades.

•Cleanunderthemowerdeck.

•Washthemachine,especiallyafterwinterapplications.

•Checkthesparkarrester(ifequipped).

•Checkthetirepressure.

•Checkthehydraulic-uidlevel.

MaintenanceService

Every100hours

Interval

MaintenanceProcedure

•Changetheengineoil.

•Checkthebattery.

•Checktheclutch.

•Checkandcleantheenginecoolingnsandshrouds(moreoftenindirtyordusty conditions).

•Checkthemower-deckbelt(s).

Every150hours

Every200hours

Every300hours

Every500hours

Every600hours

Every800hours

Every1,000hours

Beforestorage

•Inspecttheprimarylterandtheair-inletscreen.

•Changetheengine-oillter.

•Check,cleanandgapthesparkplug.

•Greasetheenginevoltageregulator.(Moreoftenifgreaseisnotpresent.)

•Replacetheprimaryairlter(moreoftenindirtyordustyconditions).

•Checktheinnerairlter(moreoftenindirtyordustyconditions).

•Adjustthecaster-pivotbearing.

•Changethehydraulicltersandhydraulicuid.

•Replacetheinnerairlter(moreoftenindirtyordustyconditions).

•Replacethefuellter.

•Replacethetransmissionbelt.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

•Paintchippedsurfaces.

•Performallmaintenanceprocedureslistedabovebeforestorage.

•Greasethetorsionidler.

•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).

•Greasethecaster-wheelhubs.

Yearly

•Greasethebrakecalipers.

•Greasethemotioncontrols.

•Applyanti-seizecompoundtothecushionknobs.

•Applydielectricgreasetothebatteryterminals.

Important:Refertoyourengineowner’smanualforadditionalmaintenanceprocedures.

Pre-Maintenance Procedures

ReleasingtheCushionfor RearAccess

Youcanreleasethecushionforrearaccesstothe machineformaintenanceoradjustment.

1.Lowertheplatform.

2.Loosenthetwistknobsoneachsideofthe machine(Figure33).

1.Twistknob

3.Removethecushionandlowerittotheplatform.

4.Performanymaintenanceoradjustmentonthe machine.

5.Raisethecushion,andslideitontothepinson bothsidesofthemachine.

6.Tightenthetwistknobs.

g032556

Figure33

2.Cushion

Lubrication

GreasingtheTorsionIdler

ServiceInterval:Yearly

GreasingtheMachine

GreasewithNo.2lithiumormolybdenumgrease.

1.DisengagethePTOandsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Cleanthegreasettingswitharag.

Note:Makesuretoscrapeanypaintoffthe

frontofthetting(s).

4.Connectagreaseguntothetting.

5.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings.

6.Wipeupanyexcessgrease.

GreasingtheAccessory Frame

Greasethepivotsoftheaccessoryframeatthe locationsshowninFigure34.

Greasethetorsionidleronthemowerdeckusing high-temperaturegreaseatthegreasettingshown inFigure35.

Important:Useonlyhigh-temperaturegrease.

Donotusegeneral-purposegrease.

g268671

Figure35

1.Greasethesepivots.

Figure34

1.Greasetting

GreasingtheFrontCaster Pivots

ServiceInterval:Yearly

Greasetype:Lithiumormolybdenumgrease

1.Removethedustcapandadjustthecaster pivots;refertoAdjustingtheCaster-Pivot

g032690

Bearing(page42).

Note:Keepthedustcapoffuntilyouhave

nishedgreasingthecasterpivots.

2.Removethehexplug.

3.Threadagreasetting(1/4inch–28taper thread)intothehole.

4.Pumpgreaseintothettinguntilitoozesout aroundthetopbearing.

5.Removethegreasettingfromthehole.

6.Installthehexpluganddustcap.

GreasingtheCaster-Wheel Hubs

ServiceInterval:Yearly

Greasetype:Lithiumormolybdenumgrease

10.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.

11.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethecasterwheelfromthecasterforks.

4.Removethesealguardsfromthewheelhub (Figure36).

Figure36

1.Sealguard2.Spacernutwithwrench

ats

12.Insertthesecondbearingandthenewsealinto thewheel.

13.Applyathread-lockingadhesivetothesecond spacernut,threadingitontotheaxlewiththe wrenchatsfacingoutward.

14.T orquethenutto8to9N∙m(71to80in-lb), loosenit,thentorqueitto2to3N∙m(20to25 in-lb).

Note:Makesurethattheaxledoesnotextend

beyondeithernut.

15.Installthesealguardsoverthewheelhuband insertthewheelintothecasterfork.

16.Installthecasterboltandtightenthenutfully.

Important:Topreventsealandbearingdamage,

checkthebearingadjustmentoftenbyspinning thecasterwheel.Thewheelshouldnotspinfreely (morethan1or2revolutions)orhaveanyside

g006115

play.Ifthewheelspinsfreely,adjustthetorque onthespacernutuntilthereisaslightamountof drag,andapplythread-lockingadhesive.

5.Remove1spacernutfromtheaxleassemblyin thecasterwheel.

Note:Thread-lockingadhesivehasbeen

appliedtolockthespacernutstotheaxle. Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly.

6.Pryouttheseals,inspectbearingsforwearor damage,andreplacethemifnecessary.

7.Packthebearingswithageneral-purpose grease.

8.Insert1bearingand1newsealintothewheel.

Note:Y oumustreplacetheseals.

9.Ifbothspacernutsintheaxleassembly havebeenremoved(orbrokenloose),apply athread-lockingadhesiveto1spacernut, threadingitontotheaxlewiththewrenchats facingoutward.

Note:Donotthreadthespacernutallof

thewayontotheendoftheaxle.Leave approximately3mm(1/8inch)fromtheouter surfaceofthespacernuttotheendoftheaxle insidethenut.

GreasingtheEngine VoltageRegulator

ServiceInterval:Every300hours(Moreoftenif

greaseisnotpresent.)

Greasetype:Dielectricgrease

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Disconnectthesparkplugwiresfromthespark plug.

4.Lightlyapplygreasetothevoltageregulator blades(Figure37).

Important:T oomuchgreasecancause

watertopoolattheconnectorandshortthe regulator.

5.Connectthesparkplug.

Figure37

1.Voltageregulator2.Regulatorblades

GreasingtheBrakeCalipers

ServiceInterval:Yearly

GreasingtheMotion Controls

ServiceInterval:Yearly

Greasetheoperator-presence-controlballjointand themotion-controlbushingforbothlevers.

Note:Useanoildripbetweentheleverbracketsto

greasethebushing,locatedinthepivottube.

g228035

Applyarust-preventativespraytothebrakecalipers yearly.

Figure38

1.Brakecaliper

g228034

g228033

1.Operator-presencecontrol

balljoint

Figure39

2.Pivottube

EngineMaintenance

EngineSafety

•Shutofftheenginebeforecheckingtheoilor

addingoiltothecrankcase.

•Keepyourhands,feet,face,clothing,andother

bodypartsawayfromthemuferandotherhot surfaces.

ServicingtheAirCleaner

ServiceInterval:Every150hours

Every300hours/Y early(whichevercomes rst)—Replacetheprimaryairlter(moreoften indirtyordustyconditions).

Every300hours—Checktheinnerairlter (moreoftenindirtyordustyconditions).

Every600hours—Replacetheinnerairlter (moreoftenindirtyordustyconditions).

Note:Checktheltersmorefrequentlyifthe

operatingconditionsareextremelydustyorsandy .

RemovingtheFilters

1.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

g012996

Figure40

1.Air-inletcover3.Air-cleanerbody

2.Air-inletscreen4.Latch

6.Releasethelatchesontheaircleanerandpull theair-cleanercoverofftheair-cleanerbody (Figure41).

7.Cleantheinsideoftheair-cleanercoverwith compressedair.

8.Gentlyslidetheprimarylteroutofthe air-cleanerbody(Figure41).

Note:Avoidknockingthelterintothesideof

thebody.

9.Removetheinnerlteronlyifyouintendto replaceit.

3.Releasethelatchesontheaircleanerand pulltheair-inletcoverofftheair-cleanerbody (Figure40).

4.Cleantheair-inletscreenandcover.

5.Installtheair-inletcoverandsecureitwiththe latches(Figure40).

1.Innerlter

2.Primarylter

3.Air-cleanercover

g012997

Figure41

4.Latch

5.Air-cleanerbody

InspectingtheFilters

1.Inspectthesafetylter.Ifitisdirty,replaceboth thesafetyandprimarylters.

Important:Donotattempttocleanthe

safetylter.Ifthesafetylterisdirty ,then theprimarylterisdamaged.

2.Inspecttheprimarylterfordamagebylooking intothelterwhileshiningabrightlightonthe outsideofthelter.Iftheprimarylterisdirty, bent,ordamaged,replaceit.

Note:Holesinthelterappearasbrightspots.

Donotcleantheprimarylter.

InstallingtheFilters

Important:Topreventenginedamage,always

operatetheenginewithbothairltersandthe coverinstalled.

1.Ifyouareinstallingnewlters,checkeachlter forshippingdamage.

ServicingtheEngineOil

Engine-OilSpecications

OilType:Detergentoil(APIserviceSJorhigher)

OilCapacity:1.65L(56oz)withthelter;1.50L

(51oz)withoutthelter

Viscosity:Seethetablebelow.

Note:Donotuseadamagedlter.

2.Ifyouarereplacingtheinnerlter,carefullyslide itintothelterbody(Figure41).

3.Carefullyslidetheprimarylteroverthesafety lter(Figure41).

Note:Ensurethattheprimarylterisfully

seatedbypushingontheouterrimwhile installingit.

Important:Donotpressonthesoft,inside

areaofthelter.

4.Installtheair-cleanercoverandsecurethe latches(Figure41).

g012991

Figure42

Note:Useasyntheticoilwith5W-20or5W-30rating,

upto4°C(40°F).

Note:Syntheticoilsprovidebetterstartingwhenthe

temperatureisbelow-23°C(-10°F).

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily

Note:Checktheoilwhentheengineiscold.

WARNING

Contactwithhotsurfacesmaycausepersonal injury.

Keepyourhands,feet,face,clothingand otherbodypartsawaythemuferandother hotsurfaces.

Important:Donotoverllthecrankcasewithoil

becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecause theenginemaybedamaged.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Checktheengine-oillevelasshownin(Figure

43).

g032691

g307458

Figure43

ChangingtheEngineOil

ServiceInterval:Aftertherst8hours

Every100hours

Note:Disposeoftheusedoilatarecyclingcenter.

1.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoil drainscompletely.

2.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

3.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

4.ChangetheengineoilasshowninFigure44.

g032710

Figure44

5.Slowlypourapproximately80%ofthespecied oilintothellertubeandslowlyaddthe additionaloiltobringittotheFullmark(Figure

45).

g027734

Figure45

ChangingtheEngine-OilFilter

ServiceInterval:Every200hours

Note:Changetheengine-oilltermorefrequently

whenoperatingconditionsareextremelydustyor sandy.

1.Draintheoilfromtheengine;refertoChanging

theEngineOil(page34).

2.Changetheengine-oillter(Figure46).

g032710

g194610

6.Starttheengineanddrivetoaatarea.

7.Checktheoillevelagain.

g027477

Figure46

Note:Ensurethattheoil-ltergaskettouches

theengine,thenrotatethelteranextra3/4turn.

3.Fillthecrankcasewiththepropertypeofnew oil;refertoEngine-OilSpecications(page32).

ServicingtheSparkPlug

CheckingtheSparkPlug

ServiceInterval:Every200hours

Makesurethattheairgapbetweenthecenterand sideelectrodesiscorrectbeforeinstallingthespark plug.

Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewspark plug(s)ifnecessary.

TypeforallEngines:Kohler2513214-c,Champion XC12YC,orequivalent

AirGap:0.75mm(0.03inch)

RemovingtheSparkPlug

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.RemovethesparkplugasshowninFigure47.

Important:Donotcleanthesparkplug(s).

Alwaysreplacethesparkplug(s)whenithasa blackcoating,wornelectrodes,anoilylm,or cracks.

Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty .

Setthegapto0.75mm(0.03inch).

g027479

Figure48

InstallingtheSparkPlug

Figure47

g265991

g027478

Figure49

g028109

CheckingtheSpark

FuelSystem

Arrester

ForMachineswithaSpark Arrester

ServiceInterval:Every50hours

WARNING

Hotexhaust-systemcomponentsmayignite fuelvaporsevenafteryoushutofftheengine. Hotparticlesexhaustedduringengine operationmayigniteammablematerials, resultinginpersonalinjuryorproperty damage.

Donotrefuelorruntheengineunlessthe sparkarresterisinstalled.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Waitforthemufertocool.

4.Ifyouseeanybreaksinthescreenorwelds, replacethearrester.

5.Ifthescreenisplugged,removethearrester, shakelooseparticlesoutofthearrester,and cleanthescreenwithawirebrush(soakthe screeninsolventifnecessary).

6.Installthearresterontheexhaustoutlet.

Maintenance

DrainingtheFuelTank

Youcandrainthefueltankbyremovingitandpouring thefueloutofthellneck;refertoRemovingtheFuel

Tank(page38).Youcanalsodrainthefueltankby

usingasiphoninthefollowingprocedure.

DANGER

Incertainconditions,fuelisextremely ammableandhighlyexplosive.Areor explosionfromfuelcanburnyouandothers andcandamageproperty.

•Drainfuelfromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopen area.Wipeupanyfuelthatspills.

•Neversmokewhendrainingfuel,andstay awayfromanopename,orwhereaspark mayignitethefuelfumes.

1.DisengagethePTO,movethemotion-control leverstotheNEUTRAL-LOCKposition,and engagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(Figure50).

4.Removethefuelcap.

5.Insertasyphonpumpintothefueltank.

6.Usingthesyphonpump,drainthefuelintoafuel container.

7.Wipeupanyspilledfuel.

Figure50

1.Fuelcap

g273861

RemovingtheFuelTank

ReplacingtheFuelFilter

1.Lowertheplatform.

2.Releasethecushion;refertoReleasingthe

CushionforRearAccess(page27).

3.Removethecrossbracket.

Figure51

1.Fueltank

4.Removethefueltankandsetitontheoperator platform.

2.Crossbracket

ServiceInterval:Every800hours/Yearly(whichever

comesrst)

Donotinstalladirtylterifitisremovedfromthefuel line.

Note:Wipeupanyspilledfuel.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Closethefuel-shutoffvalve;refertoUsingthe

Fuel-ShutoffValve(page23).

4.ReplacethefuellterasshowninFigure52.

g031413

Note:Ifyouwanttomovethefueltankfurther

fromthemachine,removethefuelandvent linesfromthetopofthetank.

g029685

Figure52

ElectricalSystem Maintenance

ElectricalSystemSafety

•Disconnectthebatteryorremovethespark-plug

wirebeforemakinganyrepairs.Disconnectthe negativeterminalrstandthepositiveterminal last.Connectthepositiveterminalrstand negativelast.

•Chargethebatteryinanopen,well-ventilated

area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated tools.

ServicingtheBattery

ServiceInterval:Every100hours

Yearly

Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof 4partswaterand1partbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.

Voltage:12V

RemovingtheBattery

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.RemovethebatteryasshowninFigure53.

g030988

Figure53

ChargingtheBattery

InstallingtheBattery

WARNING

Chargingthebatteryproducesgassesthat canexplode.

Neversmokenearthebatteryandkeepsparks andamesawayfrombattery .

Important:Alwayskeepthebatteryfullycharged

(1.265specicgravity)topreventbatterydamage whenthetemperatureisbelow0°C(32°F).

1.Removethebatteryfromthechassis;referto

RemovingtheBattery(page39).

2.Checktheelectrolytelevel.

3.Ensurethatthellercapsareinstalledonthe battery.

4.Chargethebatteryfor1hourat25to30Aor6 hoursat4to6A.

5.Whenthebatteryisfullycharged,unplugthe chargerfromtheelectricaloutlet,anddisconnect thechargerleadsfromthebatteryposts(Figure

54).

InstallthebatteryasshowninFigure55.

6.Installthebatteryontothemachineandconnect thebatterycables;refertoInstallingtheBattery

(page40).

Note:Donotrunthemachinewiththebattery

disconnected;electricaldamagemayoccur.

Figure54

1.Positivebatterypost

2.Negativebatterypost

3.Red(+)chargerlead

4.Black(-)chargerlead

g030989

Figure55

g000538

ServicingtheFuses

DriveSystem

Theelectricalsystemisprotectedbyfuses.It requiresnomaintenance.Ifafuseblows,checkthe componentorcircuitforamalfunctionorshort.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Releasetheoperatorcushionfromtherearof themachine.

4.Ifyouneedtoaccessthechargefuse,remove thefueltank;refertoRemovingtheFuelT ank

(page38).

5.Pulloutthefuseandreplaceit(Figure56).

Maintenance

AdjustingtheTracking

Ifyoupushbothmotion-controlleversforwardthe samedistanceandthemachinepullsto1side,adjust thetrackingasfollows.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Releasethecushionfromtherearofthe machine;refertoReleasingtheCushionfor

RearAccess(page27).

Note:Foreasieraccess,youcanalsoremove

thefueltank;refertoRemovingtheFuelT ank

(page38).

4.Rotatetheleftcontrolrodinquarter-turn incrementsuntilthemachinetracksstraight (Figure57).

Figure56

1.Keyswitchfuse(15A)4.Hourmeter(7.5A)

2.Accessoryport(15A)5.Chargefuse(20A)

3.Power-takeoff(PTO)fuse (10A)

6.Installthefueltank,ifremoved;referto

RemovingtheFuelTank(page38).

7.Installtheoperatorcushion.

Note:Ifthemachinepullstotheright,shorten

thecontrolrodbyrotatingittotheright.Ifthe machinepullstotheleft,lengthentherodby rotatingittotheleft.

g301335

Note:Adjustonlytheleftcontrolrodtomatch

theleftwheelspeedtotherightwheelspeed. Donotadjusttherightwheelspeed,asthis positionstherightmotion-controlleveroutofthe centerforthecontrolpanelneutral-lockslot.

Important:Donotrotatethecontrolrodtoo

far,asthismaycausethemachinetocreep inneutral.

g031531

Figure57

1.Rotatelefttolengthenthe rod.

2.Leftcontrolrod

3.Rotaterighttoshortenthe rod.

5.Checkforpropertracking,andadjusttherod asnecessary.

Note:Ifyouareunabletoachieveproper

trackingbyadjustingtheleftcontrolrod,contact yourAuthorizedServiceDealer.

6.Checkthatthemachinedoesnotcreepfrom theneutralpositionwiththeparkbrakes disengaged.

7.Installthefueltank,ifyouremovedit.

8.Installthecushion.

CheckingtheTirePressure

AdjustingtheCaster-Pivot Bearing

ServiceInterval:Every500hours/Yearly(whichever

comesrst)

1.Disengagetheblade-controlswitch(PTO),move themotioncontrolleverstotheNEUTRAL-LOCK position,andsettheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethedustcapfromthecasterandtighten thelocknut(Figure59).

ServiceInterval:Every50hours/Monthly(whichever

comesrst)

Maintaintheairpressureinthereartiresat83to97 kPa(12to14psi).

Important:Uneventirepressurecancausean

unevencut.

Note:Thefronttiresaresemi-pneumatictiresanddo

notrequireair-pressuremaintenance.

Figure58

4.Tightenthelocknutuntilthespringwashersare at,andthenbackoffa1/4turntoproperlyset thepreloadonthebearings(Figure59).

Important:Makesurethatthespring

washersareinstalledcorrectlyasshownin

Figure59.

5.Installthedustcap(Figure59).

g001055

g001297

Figure59

1.Springwashers

2.Locknut

3.Dustcap

ServicingtheCaster WheelsandBearings

Thecasterwheelsrotateonarollerbearingsupported byaspannerbushing.Ifthebearingiskeptwell lubricated,wearwillbeminimal.Failuretokeepthe bearingwelllubricatedcausesrapidwear.Awobbly casterwheelusuallyindicatesawornbearing.

1.Removethelocknutandwheelboltholdingthe casterwheeltothecasterfork(Figure60).

9.Tightenthelocknutuntilthespannerbushing bottomsagainsttheinsideofthecasterforks (Figure60).

10.Greasethettingonthecasterwheel.

RemovingtheClutchShim

ServiceInterval:Every100hours

Whentheclutchbrakehasworntothepointwhere theclutchnolongerengagesconsistently,youcan removetheshimtoextendtheclutchlife(Figure61).

Figure60

1.Locknut4.Rollerbearing

2.Bushing

3.Spannerbushing

5.Casterwheel

6.Wheelbolt

2.Remove1bushing,thenpullthespanner bushingandrollerbearingoutofthewheelhub (Figure60).

3.Removetheotherbushingfromthewheelhub andcleananygreaseanddirtfromthewheel hub(Figure60).

4.Inspecttherollerbearing,bushings,spanner bushingandtheinsideofthewheelhubforwear.

Note:Replaceanydamagedorwornparts

(Figure60).

g302539

Figure61

1.Armature5.Brakespacer

2.Fieldshell

g009453

3.Rotor7.Brakepole

4.Brake-mountingbolt

6.Shim.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Usinganaircompressor,blowoutanydebris underthebrakepoleandaroundthebrake spacers.

5.Place1bushingintothewheelhub(Figure60).

6.Greasetherollerbearingandspannerbushing, andslidethemintothewheelhub(Figure60).

7.Placethesecondbushingintothewheelhub (Figure60).

8.Installthecasterwheelintothecasterforkand secureitwiththewheelboltandlocknut(Figure

60).

g302534

Figure62

4.Checktheconditionofthewire-harnessleads, connectors,andterminals.Cleanorrepairthem asnecessary.

5.Verifythat12Vispresentattheclutchconnector whentheyouengagethePTOswitch.

6.Measurethegapbetweentherotorand armature.Ifthegapisgreaterthan1mm(0.04 inch),proceedwiththefollowingsteps:

A.Loosenbothbrakemountingbolts1/2to1

fullturnasshowninFigure63.

Note:Donotremovethebrakepolefrom

theeldshell/armature.Thebrakepole hasworntomatchthearmatureandneeds tocontinuetomatchafteryouremovethe shimtoensuretheproperbraketorque.

E.Usinga0.010inchthick-feelergauge,verify

thatagapispresentbetweentherotorand armaturefaceonbothsidesofthebrake poleasshowninFigure65andFigure66.

Note:Duetothewaytherotorand

armaturefaceswear(peaksandvalleys),it issometimesdifculttomeasurethetrue gap.

g302536

Figure65

1.Feelergauge

Figure63

1.Brake-mountingbolt

B.Usingneedle-nosepliers,orbyhand,

removetheshim.

Note:Donotdiscardtheshimuntilyou

conrmthattheclutchfunctionsproperly.

Figure64

1.Shim

g302537

g302535

Figure66

1.Feelergauge

•Ifthegapislessthan0.010inch,

theninstalltheshimandreferto

Troubleshooting(page60).

•Ifthegapissufcient,proceedtothe

safetycheckinstepF.

g302538

C.Usingapneumaticline,blowoutanydebris

underthebrakepoleandaroundthebrake spacers.

D.T orqueeachbolt(M6x1)to12.3to13.7

N∙m(9.5to10.5ft-lb).

F.Performthefollowingsafetycheck:

i.Starttheenginefromtheoperator’s

position.

ii.Makesurethatthebladesdonot

engagewhenthePTOswitchisin theOFFpositionandtheclutchis disengaged.

Note:Iftheclutchdoesnot

disengage,installtheshim,andrefer toTroubleshooting(page60).

iii.EngageanddisengagethePTO

switch10consecutivetimesto ensurethattheclutchisfunctioning properly.

Note:Iftheclutchdoesnotengage

properly,refertoTroubleshooting

(page60).

CoolingSystem Maintenance

CleaningtheAir-Intake Screen

ServiceInterval:Beforeeachuseordaily

Beforeeachuse,removeanybuildupofgrass,dirt, orotherdebrisfromthecylinderandcylinder-head coolingns,air-intakescreenontheywheelend, andthecarburetor-governorleversandlinkage.This helpsensureadequatecoolingoftheengineandthe correctenginespeed,anditreducesthepossibilityof overheatingormechanicaldamagetotheengine.

CleaningtheCooling

CheckingtheWheel-Lug Nuts

ServiceInterval:Aftertherst100hours—Checkthe

wheel-lugnuts.

Checkandtorquethewheel-lugnutsto115to142 N∙m(85to105ft-lb).

System

ServiceInterval:Every100hours—Checkand

cleantheenginecoolingnsand shrouds(moreoftenindirtyordusty conditions).

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removetheair-intakescreenandfanhousing (Figure67).

4.Cleanthedebrisandgrassfromtheengine parts.

5.Installtheair-intakescreenandthefanhousing (Figure67).

1.Guardandengine

air-intakescreen

2.Fanhousing

g031439

Figure67

3.Engine-oilcooler

BrakeMaintenance

BeltMaintenance

TestingtheParkingBrake

ServiceInterval:Beforeeachuseordaily

Beforeeachuse,testtheparkingbrakeonbotha levelsurfaceandslope.

Alwaysengagetheparkingbrakewhenyoustopthe machineorleaveitunattended.Iftheparkingbrake doesnotholdsecurely ,adjustit.

1.DisengagethePTOandengagetheparking brake

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Disengagetheparkingbrake.

4.Engagethebrakeleverandensurethatthe machinedoesnotmove.

5.Adjustthebrakeifneeded.

AdjustingtheBrakes

1.Removethefueltank;refertoRemovingthe

FuelT ank(page38).

CheckingtheBelts

ServiceInterval:Every100hours—Checkthe

mower-deckbelt(s).

Checkbeltsforcracks,frayededges,burnmarks, wear,signsofoverheating,oranyotherdamage.

Thesignsofawornmowerbeltaresquealingwhile thebeltisrotating,bladesslippingwhileyouare cuttinggrass,frayedbeltedges,burnmarks,and cracks.Replacethemowerbeltifyoudetectanyof thesesigns.

ReplacingtheMower-Deck Belt

1.DisengagethePTOandengagetheparking brake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.ReplacethebeltasshowninFigure69.

2.Loosentheboltonthecableclampontheleft sideofthemachine.

Figure68

1.Cable

2.Cableclamp

3.Pulldownonthecablesuntiltheyaretaut.

4.Tightenthenut.

3.Boltandnut

g031396

5.Installthefueltank,crossbracket,andcushion.

ReplacingtheTransmission Belt

ServiceInterval:Every1,000hours—Replacethe

transmissionbelt.

1.Removethefueltank;refertoRemovingthe

FuelT ank(page38).

2.Removethehydraulic-reservoircap.

3.Locatethedrainplugsinthebottomofthe transmissionandplaceadrainpanunderthe plug(Figure70).

Figure69

g267274

Figure70

1.Drainplug

g031344

4.Allowthehydraulicuidtodrainfromthe machine.

5.Removethelowerhydraulichose(Figure71).

g031345

Figure71

1.Lowerhydraulichose3.Tensionspring

2.Transmissionbelt

6.Removethetensionspring(Figure71).

CAUTION

Thespringisundertensionwhen installedandcancausepersonalinjury .

Wearsafetyglassesandbecarefulwhen removingthespring.

ControlsSystem Maintenance

Adjustingthe

7.Removethedeckbeltfromtheclutchandclutch stop(Figure71).

8.Installthenewbelt.

9.Installthetensionspringandlowerhydraulic hose.

10.Installthedrainplugsandtorqueto22to27 N∙m(16to20ft-lb).

11.Addhydraulicuidtothelllevel.

12.Installthehydraulic-reservoircap.

13.Runthemachinefor10minutesandverifythat thehydraulicuidisatthecorrectlevel.

Motion-ControlLevers

Ifthemotion-controlleversdonotalignhorizontally , adjustthemotion-controllevers.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Pushthemotion-controlleversdownoutofthe NEUTRAL-LOCKposition(Figure72).

4.Checkiftherightmotion-controlleveraligns horizontallywiththeleftmotion-controllever (Figure72).

Figure72

1.Leftmotion-controllever3.Checkthehorizontal

2.Rightmotion-controllever

intheNeutral-lockposition

alignmenthere

4.Rightmotion-controllever

Note:T oadjusttherightmotion-controllever

horizontally,adjustthecam.

5.Releasethecushionfromtherearofthe machine.

6.Loosenthenutholdingthecam(Figure73).

g009436

Figure73

1.Cam

7.Adjustthecamuntilitalignswiththeleft motion-controlleverandtightenthenutforthe cam.

2.Nut

Note:Movingthecamclockwise(inthevertical

position)lowersthehandle;movingthecam counterclockwise(intheverticalposition)raises thehandle.

HydraulicSystem Maintenance

HydraulicSystemSafety

•Seekimmediatemedicalattentionifuidisinjected

intoskin.Injecteduidmustbesurgicallyremoved withinafewhoursbyadoctor.

•Ensurethatallhydraulic-uidhosesandlinesare

g031538

ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.

•Keepyourbodyandhandsawayfrompinhole

leaksornozzlesthatejecthigh-pressurehydraulic uid.

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem

beforeperforminganyworkonthehydraulic system.

Important:Ensurethattheatportionofthe

camdoesnotgoaboveaverticalposition (rightorleft);otherwiseyoumaydamagethe switch.

8.Repeatsteps3through7fortheleft motion-controllever.

HydraulicSystem Specications

HydraulicFluidType:T oro

hydraulicuid

HydraulicSystemFluidCapacity:4.7L(159oz)

HYPR-OIL

Important:Usetheuidspecied.Otheruids

coulddamagethesystem.

™

500

CheckingtheHydraulic Fluid

ServiceInterval:Aftertherst8hours

Every50hours

Note:Checkthehydraulic-uidlevelwhentheuid

iscold.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Waitforthemachinetocool.

4.Cleantheareaaroundthecapandthellerneck ofthehydraulictank(Figure74).

Figure74

1.Hydraulic-tankcap

2.Colduidlevel

5.Removethecapfromthellerneck(Figure74).

Note:Lookinsidetochecktheuidlevelin

thereservoir.

6.Adduidtothereservoiruntilitreachesthe reachestheminimumcoldlllevel.

7.Installthecaponthellerneck.

ReplacingtheHydraulic FluidandFilters

4.Removethehydraulic-reservoircap.

5.Locatethedrainpluginthebottomofeach transmissionandplaceadrainpanunderthe plugs(Figure75).

g301336

g268090

Figure75

1.Drainplug

2.Hydrauliclter

6.Removethedrainplugs.

7.Allowthehydraulicuidtofullydrainfromthe machine.

8.Removethehydraulicltercapandlterfrom eachtransmission.

9.Installnewhydrauliclterswiththespringside facingoutandinstalltheltercaps.

10.Installthedrainplugsandtorqueto22to27 N∙m(16to20ft-lb).

ServiceInterval:Aftertherst50hours

Every500hours/Y early(whichevercomes rst)—Changethehydraulicltersandhydraulic uid.

Changethehydraulicuidmorefrequentlyinsevere conditionsorinahotoperatingclimate.Contact yourAuthorizedServiceDealerforahydraulickitto replacethehydrauliclters.

WARNING

Hothydraulicuidcancausesevereburns.

Allowthehydraulicuidtocoolbefore performinganymaintenanceonthehydraulic system.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Removethefueltank;refertoRemovingthe

FuelT ank(page38).

11.Loosentheventplugineachtransmissionso thatitislooseandwobbles(Figure76).

Note:Thisallowsairtoescapethehydraulic

systemasyouaddhydraulicuid.

g031544

Figure76

Lefttransmissionshown

1.Ventplug

12.Slowlyadduidtothehydraulictankuntilit startstocomeout1oftheventplugs.

Important:Usetheuidspeciedin

HydraulicSystemSpecications(page49)or

equivalent.Otheruidscouldcausesystem damage.

Important:Monitorthelevelofuidinthe

hydraulictanksothatyoudonotoverllit.

MowerDeck Maintenance

BladeSafety

13.Tightentheventplugs.

14.Installthehydraulic-tankcap.

15.Installthefueltank.

16.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.

17.Shutofftheengineandcheckforleaks.

Note:If1orbothwheelsdonotdrive,referto

BleedingtheHydraulicSystem(page51).

BleedingtheHydraulic System

Thetractionsystemisself-bleeding,however,itmay benecessarytobleedthesystemifuidischanged orafterworkisperformedonthesystem.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

Awornordamagedbladecanbreak,andapieceof thebladecouldbethrowntowardyouorbystanders, resultinginseriouspersonalinjuryordeath.

•Inspectthebladesperiodicallyforwearordamage.

•Usecarewhencheckingtheblades.Wrapthe

bladesorweargloves,andusecautionwhen servicingtheblades.Onlyreplaceorsharpenthe blades;neverstraightenorweldthem.

•Alwaysinspectthemachinetoensurethatthe

bladesandbladeboltsarenotwornordamaged. Replacewornordamagedbladesandboltsinsets topreservebalance.

•Onmulti-bladedmachines,takecareasrotating1

bladecancauseotherbladestorotate.

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement, keepextrabladesonhand.

3.Raisetherearofthemachineontojackstands highenoughtoraisethedrivewheelsoffthe ground.

4.Starttheengineandmovethethrottlecontrolto theidleposition.

Note:Ifthedrivewheeldoesnotrotate,assist

thepurgingofthesystembycarefullyrotating thetireintheforwarddirection.

5.Checkthehydraulicuidlevelasitdrops,and adduidasrequiredtomaintaintheproperlevel.

6.Repeatthisprocedurefortheoppositewheel.

BeforeInspectingorServicingthe Blades

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,and disconnectthespark-plugwiresfromthespark plugs.

InspectingtheBlades

ServiceInterval:Beforeeachuseordaily

1.Inspectthecuttingedges(Figure77).

2.Iftheedgesarenotsharporhavenicks,remove andsharpentheblade;refertoSharpeningthe

Blades(page52).

3.Inspecttheblades,especiallyinthecurvedarea.

4.Ifyounoticeanycracks,wear,oraslotforming inthisarea,immediatelyinstallanewblade (Figure77).

WARNING

Abladethatisbentordamagedcould breakapartandcouldcriticallyinjure youorbystanders.

•Alwaysreplaceabentordamaged bladewithanewblade.

Figure77

1.Cuttingedge3.Wear/slotforming

2.Curvedarea4.Crack

CheckingforBentBlades

1.Rotatethebladesuntiltheendsfaceforward andbackward.

2.Measurefromalevelsurfacetothecutting edge,positionA,oftheblades(Figure78).

g006530

theedgesorsurfacesoftheblade.

RemovingtheBlades

Replacethebladesiftheyhitasolidobject,orifthe bladeisoutofbalanceorbent.

1.Placeawrenchontheatofthespindleshaftor holdthebladeendusingaragorthicklypadded glove.

2.Removethebladebolt,bushing,andbladefrom thespindleshaft(Figure79).

•Donotleorcreatesharpnotchesin

Figure78

1.Measureherefromblade tohardsurface

2.PositionA

3.Rotatetheoppositeendsofthebladesforward.

4.Measurefromalevelsurfacetothecuttingedge

ofthebladesatthesamepositionasinstep2 above.

Note:Thedifferencebetweenthedimensions

obtainedinsteps2and3mustnotexceed3mm (1/8inch).

Note:Ifthisdimensionexceeds3mm

(1/8inch),replacetheblade.

g000975

g295816

Figure79

1.Sailareaoftheblade

2.Blade5.Bladebolt

3.Flatofthespindleshaft

4.Bushing

SharpeningtheBlades

1.Usealetosharpenthecuttingedgeatboth endsoftheblade(Figure80).

Note:Maintaintheoriginalangle.

Note:Thebladeretainsitsbalanceifthesame

amountofmaterialisremovedfrombothcutting edges.

Figure80

1.Sharpenatoriginalangle.

2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure81).

Note:Ifthebladestaysinahorizontalposition,

thebladeisbalancedandcanbeused.

Note:Ifthebladeisnotbalanced,lesome

metalofftheendofthesailareaonly(Figure80).

Figure81

g000552

g298850

Figure83

1.Topspindlenut3.Bladebolt

g000553

2.Flatofthespindleshaft

1.Blade2.Balancer

3.Repeatthisprocedureuntilthebladeis balanced.

InstallingtheBlades

1.Installthebushingthroughthebladewiththe bushingangeonthebottom(grass)sideofthe blade(Figure82).

Figure82

1.Bushing

3.Applycopper-basedlubricantorgreasetothe threadsofthebladeboltasneededtoprevent seizing.Installthebladeboltnger-tight.

4.Placeawrenchontheatofthespindleshaft andtorquethebladeboltto75to81N∙m(55 to60ft-lb).

RemovingtheMowerDeck

1.Shutofftheengine,waitforallmovingpartsto stop,engagetheparkingbrake,andremove thekey.

2.Usetheheight-of-cutlevertolowerthemower deckontowoodblocks.

3.Removethemower-deckbelt;refertoReplacing

theMower-DeckBelt(page46).

4.Removethe2boltsand2nutsconnectingthe

g255205

strutbrackettotheframe(Figure84).

Note:Retainthefastenerswiththestrut

bracket.

2.Installthebushing/bladeassemblyintothe spindleshaft(Figure83).

Figure84

Rightsideshown

1.Bolt3.Nut

2.Strutbracket

5.Removethe2bolts,2nuts,andwasher connectingthemower-deckhangerstothelift platesforbothsidesofthemowerdeck(Figure

85andFigure86).

Note:Retainthemountinghardwarewiththe

deckchains.

g033736

g033738

Figure86

LeftSideof60-inchDeckShown

1.Bolt

2.Washer5.Mower-deckhanger

3.Nut

4.Liftplate

6.Rotatethecasterwheelsforward.

7.Slidethemowerdeckoutfromunderthe machine.

8.Ifyouareusingthemachineinawinter applicationwithoutaPTO-poweredattachment, removetheclutchtopreventcorrosionas follows:

A.Unplugthewireharnessfromtheclutch

(Figure42).

Figure85

LeftSideof52-inchDeckShown

1.Liftplate

2.Bolt5.Mower-deckhanger

3.Washer

4.Nut

g033737

g226599

Figure87

1.Wireharness

2.Clutch

3.Washer

4.Springwasher

5.Bolt

B.Removethebolt,washer,springwasher,

andclutch(Figure42).

LevelingtheMowerDeck

C.Applyanti-seizecompoundtothecrank

shaft,theninstallthebolt,washer,spring washer,andaspacer(Toropartno. 136-5411)totheshaft(Figure88).

Figure88

1.Crankshaft4.Springwasher

2.Spacer

3.Washer

D.Applydielectricgreasetotheconnectorand

useacabletietosecureittothemachine.

5.Bolt

InstallingtheMowerDeck

1.Slidethemowerdeckunderthemachine.

2.Rotatethecasterwheelsrearward.

3.Connectthedeckhangerstotheliftplatesusing the2bolts,2nuts,and2washersthatyou retainedforeachsideofthemowerdeck.

PreparingtheMachine

Ensurethatthemowerdeckislevelanytimeyou installthemowerdeckorwhenyouseeanuneven cutonyourlawn.

Levelthemowerdecksidetosidebeforeadjusting thefront-to-rearslope.

1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.

2.Shutofftheengine,removethekey,and disconnectthespark-plugwiresfromthespark plugs.

3.Checkthetirepressureofbothdrivetires;refer

g226598

toCheckingtheTirePressure(page42).

4.Checkthemowerdeckforbentblades;remove andreplaceanybentblades;refertoServicing

theCuttingBlades(page51).

5.Lowerthemowerdecktothe76mm(3inch) height-of-cutposition.

CheckingtheMowerDeck Side-to-SideHeight

1.Adjusttherear-tirepressure.

2.Ensurethatthebladesarenotbent;referto

CheckingforBentBlades(page52).

3.Positionthebladessidetoside.

4.MeasureattheBandClocationsfromalevel surfacetothecuttingedgeofbladetips(Figure

89).

Note:Mountthefronthangerbracketsonthe

outsideofthefrontliftarmsfor52-inchdecks (Figure85).Mountthefronthangerbracketson theinsideofthefrontliftarmsfor60-inchdecks (Figure86).

Note:T orquetheboltsto38to49N∙m(28to

36ft-lb).

4.Installthe2boltsthatyouretainedtoconnect thestrutbrackettotheframe(Figure84).

Note:T orquetheboltsto61to75N∙m(45to

55ft-lb).

5.Installthemower-deckbelt;refertoReplacing

theMower-DeckBelt(page46).

6.Levelthemowerdeck;refertoLevelingthe

MowerDeckfromSidetoSide(page56)and LevelingtheMowerDeckfromFronttoRear (page56).

Figure89

1.Measurefromalevel surface

5.ThedifferencebetweenmeasurementsBandC

shouldbenomorethan6mm(1/4inch).

2.Measurethebladeat

pointsBandC

g006888

Note:Ifitisnotcorrect,refertoLevelingthe

MowerDeckfromSidetoSide(page56).

LevelingtheMowerDeckfrom SidetoSide

1.Loosenthesidenutandjamnutintheyokes youwanttoadjust(Figure90).

g001041

Figure91

Figure90

1.Topbolt

2.Jamnut5.Adjusttheseyokesto

3.Yoke6.Adjusttheseyokesto

4.Sidenut

adjusttherightsideofthe mowerdeck.

adjusttheleftsideofthe mowerdeck.

2.Rotatethetopboltoftheyokestoadjustthe heightofthemowerdeck(Figure90).

Note:Rotatetheboltsclockwisetoraisethe

deck;rotatetheboltcounterclockwisetolowerit.

3.Tightenthejamnutsandsidebolts.

4.Checktheside-to-sideheight;refertoChecking

theMowerDeckSide-to-SideHeight(page55).

1.Measurethebladeat

pointsAandB

2.Measurefromalevel surface

4.Ifthefront-to-rearpitchisnotcorrect,referto

LevelingtheMowerDeckfromFronttoRear

g032694

(page56).

LevelingtheMowerDeckfrom FronttoRear

1.Loosenthejamnutandsideboltintheyokes thatyouwanttoadjust(Figure92).

CheckingtheMowerDeck Front-to-RearPitch

1.Adjustthetirepressureinthereartirestothe correctspecications.

2.Position1bladefront-to-rear.MeasureatAand Blocationsfromalevelsurfacetothecutting edgeofthebladetips(Figure91).

Note:Themowerbladeshouldbe6mm(1/4

inch)lowerinfrontatAthanintherearatB.

3.Rotatethebladesandrepeatforotherblades.

Figure92

1.Topbolt

2.Jamnut5.Adjusttheseyokesto

3.Yoke6.Adjusttheseyokesto

4.Sidenut

adjustthefrontsideofthe mowerdeck.

adjusttherearsideofthe mowerdeck.

2.Rotatethetopboltoftheyokestoadjustthe heightofthemowerdeck(Figure92).

g032695

Note:Rotatetheboltclockwisetoraisethe

deck;rotatetheboltcounterclockwisetolowerit.

3.Tightenthejamnutsandsidebolts.

AdjustingtheDeck-Lift Spring

4.Checkthefront-to-rearpitch;refertoChecking

theMowerDeckFront-to-RearPitch(page56).

MatchingtheHeight-of-Cut

1.Checkthereartirepressure.

2.Settheheight-of-cuttothe76mm(3inch) position;refertoAdjustingtheHeight-of-Cut

(page20).

3.Withthemachineonlevelsurface,position1 bladefront-to-rear.

4.MeasureatA,andfromalevelsurfacetothe cuttingedgeofthebladetips(Figure93).

Note:Themeasurementshouldbe76mm(3

inches).

Note:Adjustingthecompressionspringaltershow

muchthedeckoatsandtheamountofeffortneeded toliftthedeckwhenusingtheheight-of-cutlever.

•Morespringextensionreducestheleverliftforce

requiredandcausesthedecktooatmore.

•Lessspringextensionincreasestheleverliftforce

requiredandcausesthedecktooatless.

1.Raisetheheight-of-cutleverandlockitintothe transportposition.

2.Checkthedistancebetweenthespringnut andtherearsideoftheweldedmountbracket (Figure94).

3.Ensurethatthelengthisbetween47to50mm (1.8to2inches)asshowninFigure94.

4.Ifneeded,adjustthedistancebyadjustingthe boltonthefrontofthemountbracket(Figure94).

Figure93

1.Measurefromalevel surface

2.Measurethebladeatpoint

5.Ifthemeasurementisnotcorrect,locatethe

front2yokesonthemachine(Figure92).

6.Loosenthesideboltandjamnutoftheyokes.

7.Adjustthetopboltoftheyokesuntiltheblade

tipsmatch76mm(3inches).

8.Tightenthejamnutsandsidebolts.

g000975

1.Deck-liftspring

2.Springnut

3.Rearsideofthemount bracket

Figure94

4.Adjustmentbolt

5.Lengthisbetween47to 50mm(1.8to2inches).

g032696

5.Repeatthisprocedurefortheoppositedeck-lift spring.

ReplacingtheGrass Deector

WARNING

Anuncovereddischargeopeningcouldallow themachinetothrowobjectstowardyouor bystanders,resultinginseriousinjury.Also, contactwiththebladecouldoccur.

Donotoperatethemachineunlessyouinstall acoverplate,amulchplate,grassdeector, orbagger.

1.Removethelocknut,bolt,spring,andspacer holdingthedeectortothepivotbrackets (Figure95).

Cleaning

CleaningundertheMower Deck

ServiceInterval:Beforeeachuseordaily

Beforeeachuseordaily

Removethegrassbuildupunderthemowerdaily.

1.Parkthemachineonalevelsurface,disengage thePTO,movethemotion-controlleverstothe NEUTRAL-LOCKposition,andengagetheparking brake.

2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.

3.Raisethefrontofthemachineandusejack standstosupportthemower.

DisposingofWaste

Figure95

1.Bolt

2.Spacer6.Grassdeector

3.Locknut

4.Spring

2.Removethedamagedorworngrassdeector.

3.Placethespacerandthespringontothegrass deector.

4.Place1J-hookendofthespringbehindthe deckedge.

5.Spring(installed)

7.J-hookendofthespring

Note:Makesurethat1J-hookendofspringis

installedbehinddeckedgebeforeinstallingthe boltasshowninFigure95.

Engineoil,batteries,hydraulicuid,andengine coolantarepollutantstotheenvironment.Disposeof theseaccordingtoyourstateandlocalregulations.

g015594

5.Installtheboltandthenut.

6.Place1J-hookendofthespringaroundthe grassdeector(Figure95).

Important:Thegrassdeectormustbeable

torotate.Liftthedeectoruptothefullopen position,andensurethatitrotatesintothe full-downposition.

Storage

E.Disposeoffuelproperly;recycleitaccording

tolocalregulations.

StorageSafety

•Lettheenginecoolbeforestoringthemachine.

•Donotstorethemachineorfuelnearamesor

drainthefuelindoors.

CleaningandStorage

ServiceInterval:Beforestorage

Beforestorage

1.Disengagethepowertakeoff(PTO),engagethe parkingbrake,shutofftheengine,andremove thekey.

2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especially theengine.

Important:Youcanwashthemachine

withamilddetergentandwater.Donot pressure-washthemachine.Avoidexcessive useofwater,especiallynearthedrivesystem andengine.Pressure-washingcanforcedirt andwaterintocriticalparts,suchasspindle bearingsandelectricalswitches.

Important:Donotstorefuelcontaining

stabilizer/conditionerlongerthan thedurationrecommendedbythe fuel-stabilizermanufacturer.

10.Removethesparkplug(s)andcheckits condition;refertoServicingtheSparkPlug

(page36).

11.Withthesparkplug(s)removedfromtheengine, pour15ml(2tablespoons)ofengineoilintothe spark-plughole,andusethestartertocrankthe engineanddistributetheoilinsidethecylinder.

12.Installthesparkplug(s)butdonotconnectthe wiretothesparkplug(s).

13.Checkandtightenallfasteners.Repairor replaceanypartthatisdamagedormissing.

14.Paintallscratchedorbaremetalsurfaceswith paintfromanAuthorizedServiceDealer.

15.Storethemachineinaclean,dry ,garageor storagearea.Removethekeyfromtheswitch andstoreitinamemorableplace.Coverthe machinetoprotectitandkeepitclean.

3.Cleananydirtandchafffromtheoutsideofthe enginecylinder-headnsandblowerhousing.

4.Checkthebrake;refertoT estingtheParking

Brake(page46).

5.Servicetheaircleaner;refertoServicingtheAir

Cleaner(page31).

6.Greasethemachine;refertoLubrication(page

28).

7.Changetheengineoil;refertoServicingthe

EngineOil(page32).

8.Checkthetirepressure;refertoCheckingthe

TirePressure(page42).

9.Forlong-termstorage,dothefollowing:

A.Addfuelstabilizer/conditionertothefuelin

thetankasdirectedbythefuelstabilizer manufacturer.

B.Runtheenginetodistributetheconditioned

fuelthroughthefuelsystemfor5minutes.

C.Shutofftheengine,allowittocool,and

drainthefueltank;refertoDrainingthe

FuelT ank(page37),oroperatetheengine

untilitshutsoff.

D.Starttheengineandallowittorununtilit

shutsoff.Repeatwiththechokeengaged(if applicable)untiltheenginedoesnotstart.

Troubleshooting

Problem

Theenginedoesnotstart,startshard,or failstokeeprunning.

Theenginelosespower.

PossibleCauseCorrectiveAction

1.Thefueltankisemptyortheshutoff valveisclosed.

2.Aspark-plugwireislooseor disconnected.

3.Asparkplugispitted,fouled,orthe gapisincorrect.

4.Theaircleanerisdirty.

5.Dirtisinthefuellter.5.Replacethefuellter.

6.Dirt,water,orstalefuelisinthefuel system.

7.Thegapbetweenthesafety-interlock switchesisnotcorrect.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theaircleanerisdirty.

3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.

4.Thecoolingnsandairpassages undertheengineblowerhousingare plugged.

5.Asparkplugispitted,fouled,orthe gapisincorrect.

6.Theventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.

7.Dirtisinthefuellter.7.Replacethefuellter.

8.Dirt,water,orstalefuelisinthefuel system.

1.Fillthefueltankwithfuelandopenthe valve

2.Installthewireonsparkplug.

3.Installanew,correctlygappedspark plug.

4.Servicetheair-cleanerelement.

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

2.Servicetheair-cleanerelement.

4.Removetheobstructionfromthe coolingnsandairpassages.

5.Installanew,correctlygappedspark plug.

8.ContactanAuthorizedServiceDealer.

Theengineoverheats.

Themachinedoesnotdrive.

Thereisabnormalvibration.

1.Theengineloadisexcessive.1.Reducethegroundspeed.

2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.

3.Thecoolingnsandairpassages undertheengineblowerhousingare plugged.

1.Thehydraulic-uidreservoirislow.1.Addhydraulicuidtothereservoir.

2.Airisinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.

3.Apump-drivebeltslips.3.Replacethepump-drivebelt.

4.Apump-drivebeltidlerspringis missing.

5.Thepump-bypassvalvesareopen.5.Tightenthebypassvalves.T orqueto

1.Cuttingblade(s)is/arebentor unbalanced.

2.Ablade-mountingboltisloose.2.Tightentheblade-mountingbolt.

3.Theengine-mountingboltsareloose.3.Tightentheengine-mountingbolts.

4.Anenginepulley,idlerpulley,orblade pulleyisloose.

5.Anenginepulleyisdamaged.

6.Abladespindleisbent.

3.Removetheobstructionfromthe coolingnsandairpassages.

4.Replacethepump-drivebeltidler spring.

12to15N∙m(9to11ft-lb).

1.Installnewcuttingblade(s).

4.Tightentheappropriatepulley.

ContactanAuthorizedServiceDealer.

6.ContactanAuthorizedServiceDealer.

Problem

PossibleCauseCorrectiveAction

Thecuttingheightisuneven.

Thebladesdonotrotate.

1.Blade(s)arenotsharp.1.Sharpentheblade(s).

2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).

3.Themowerdeckisnotlevel.3.Levelthemowerdeckside-to-side

4.Themowerdeckpitchiswrong.

5.Theundersideofmowerdeckisdirty.5.Cleantheundersideofthemower

6.Thetirepressureisnotcorrect.6.Adjustthetirepressure.

7.Abladespindleisbent.

1.Apump-drivebeltisworn,looseor broken.

2.Apump-drivebeltisoffpulley.

3.Amower-deckbeltisworn,looseor broken.

4.Amower-deckbeltisoffthepulley.

5.Anidlerspringisbrokenormissing.5.Replacethespring.

6.Theelectricclutchisoutofadjustment.

7.Theclutchconnectororwireis damaged.

8.Theelectricclutchisdamaged.

9.Thesafety-interlocksystemprevents bladerotation.

10.ThePTOswitchismalfunctioning.10.ContactanAuthorizedServiceDealer.

position.

4.Adjustthefront-to-rearpitch.

deck.

7.ContactanAuthorizedServiceDealer.

1.Checkthebelttension.

2.Installthedrivebeltandcheckthe adjustingshaftsandbeltguidesforthe correctposition.

3.Installthenewdeckbelt.

4.Installthedeckpulleyandcheckthe idlerpulley,idlerarmandspringforthe correctpositionandfunction.

6.Adjusttheclutchairgap.

7.ContactanAuthorizedServiceDealer.

8.ContactanAuthorizedServiceDealer.

9.ContactanAuthorizedServiceDealer.

Theclutchdoesnotengage.

Themalfunctionindicatorlight(MIL) comeson.

1.Thefuseisblown.

2.Thereislowvoltagesupplyatthe clutch.

3.Thecoilisdamaged.3.Replacetheclutch.

4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead

5.Therotor/armatureairgapistoolarge.

1.Theengineistoohot.

2.Thereisoldfuelinthefueltank.2.Usenewfuel.

3.Thefuel-shutoffvalveisnotopen completely.

4.Theaircleanerisdirty.4.Makesurethattheaircleanerand

5.Thebatteryisnotcharged.

Incorrectfuelltersarebeingusedor thefuelltersaredirty.

7.Theconnectionstothesensors electroniccontrolunit(ECU)andfuel injectorsarenotsecuredproperly .

Thereislowvoltagefromthebattery.

9.Afuseisblown.9.Checkandreplaceanyblownfuses.

1.Replacethefuse.Checkthecoil resistance,batterycharge,charging system,andwiringconnections,and replacecomponentsifnecessary.

2.Checkthecoilresistance,battery charge,chargingsystem,andwiring connectionsandreplacepartsif necessary.

wireorelectricalsystem.Cleanthe connectorcontacts.

5.Removetheshimorreplacetheclutch.

1.Turntheengineoffandletitcool.

3.Openthefuel-shutoffvalve.

precleanerareclean.Replacethemif necessary.

Chargeorreplacethebattery .

6.ContactanAuthorizedServiceDealer.

7.ContactanAuthorizedServiceDealer.

Ensurethatthebatteryisfullycharged.

Schematics

ElectricalSchematic—138-8898(Rev.B)

g301844

Notes:

CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:

WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.

Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all

AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.

•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies

makingsimilarproductsmayhavenosuchrequirement.

•TheenforcementofProp65isinconsistent.

•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora

productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromT oroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,T orohaselectedtoprovidetheProp65warnings.Moreover,ifTorodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.

RevA

Toro 72523 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual