Toro 74163, 74167 Operator's Manual

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Page 1

Form No. 3329–863

Z149 and Z153

Z Master with 52in SFS Side Discharge Mower

Model No. 74163—Serial No. 240000001 and Up Model No. 74167—Serial No. 240000001 and Up

Operator ’s Manual

Original Instructions (EN)

Page 2

Warning

CALIFORNIA

Proposition 65 Warning

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Important This engine is not equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

Ce système d’allumage par étincelle de véhicule est conforme à la norme NMB-002 du Canada.

The enclosed Engine Owner’s Manual is supplied for information regarding The U.S. Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance and warranty.

Keep this engine Owner’s Manual with your unit. Should this engine Owner’s Manual become damaged or illegible, replace immediately. Replacements may be ordered through the engine manufacturer.

Contents

Page

Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .

Slope Chart 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety and Instruction Decals 9. . . . . . . . . . . . . . . .

Gasoline and Oil 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 14. . . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 14. . . . . . . . . . . . . . . .

Filling the Fuel Tank 14. . . . . . . . . . . . . . . . . . . . . .

Checking the Engine Oil Level 14. . . . . . . . . . . . . .

Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Rollover Protection System (ROPS) 15. .

Think Safety First 16. . . . . . . . . . . . . . . . . . . . . . . . .

Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 17. . . . . . . . . . . . . . . .

Starting and Stopping the Engine 18. . . . . . . . . . . . .

Operating the Power Take Off (PTO) 19. . . . . . . . . .

The Safety Interlock System 19. . . . . . . . . . . . . . . .

Page

Driving Forward or Backward 20. . . . . . . . . . . . . . .

Stopping the Machine 20. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Height-of-Cut 21. . . . . . . . . . . . . . . . .

Adjusting the Anti-Scalp Rollers 21. . . . . . . . . . . . .

Positioning the Seat 22. . . . . . . . . . . . . . . . . . . . . . .

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

Operating with Side Discharge 22. . . . . . . . . . . . . . .

Transporting the Machine 23. . . . . . . . . . . . . . . . . . .

Loading Machines 23. . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 24. . . . . . . . . . . . . . . . . . . . .

Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 25. . . . . . . . .

Servicing the Cutting Blades 26. . . . . . . . . . . . . . . .

Cleaning the Cooling System 28. . . . . . . . . . . . . . . .

Servicing the Air Cleaner 28. . . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 29. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 31. . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 31. . . . . . . . . . . . . . . . . . .

Draining the Fuel Tank 32. . . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 32. . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 33. . . . . . . . . . . . . . . . . .

Servicing the Hydraulic System 34. . . . . . . . . . . . . .

Adjusting the Handle Neutral Position 36. . . . . . . . .

Setting the Hydraulic Pump Neutral Position 37. . . .

Adjusting the Tracking 38. . . . . . . . . . . . . . . . . . . . .

Adjusting the Caster Pivot Bearing 38. . . . . . . . . . .

Checking the Wheel Hub Slotted Nut 39. . . . . . . . .

Leveling the Mower at Three Positions 39. . . . . . . .

Adjusting the Push Arms 41. . . . . . . . . . . . . . . . . . .

Cleaning Under the Mower 41. . . . . . . . . . . . . . . . .

Inspecting the Belts 41. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 41. . . . . . . . . . . . . . . . . .

Replacing the Pump Drive Belt 42. . . . . . . . . . . . . .

Adjusting the Parking Brake 43. . . . . . . . . . . . . . . .

Servicing the Fuses 43. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 44. . . . . . . . . . . . . . . . . . . . . .

Replacing the Grass Deflector 46. . . . . . . . . . . . . . .

Waste Disposal 47. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch 47. . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch Disposal 47. . . . . . . . . . . . . . . .

Wiring Diagram 48. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 49. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 52. . . . . . . . . . . . .

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Printed in the USA

Page 3

Introduction

Safety

Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.

Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 illustrates the location of the model and serial numbers on the product.

m–3648

Figure 1

1. Location of the model and serial numbers

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

Model No.

Serial No.

This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning, and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means CAUTION, WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

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

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

Safe Operating Practices

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

Training

• Read the Operator’s Manual and other training material.

If the operator(s) or mechanic(s) can not read English it is the owner’s responsibility to explain this material to them.

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for

accidents or injuries occurring to himself or herself, other people or property.

Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions.

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

Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions.

This manual uses two other words to highlight information.

Important calls attention to special mechanical

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

Preparation

• Evaluate the terrain to determine what accessories and

attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer.

• Wear appropriate clothing including hard hat, safety

glasses and hearing protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be used and

remove all objects such as rocks, toys and wire which can be thrown by the machine.

Page 4

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use only an approved container

• Never remove gas cap or add fuel with engine

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

• Never refuel or drain the machine indoors.

• Check that operator’s presence controls, safety switches

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

• Use care when approaching blind corners, shrubs, trees,

or other objects that may obscure vision.

Slope Operation

• Do not mow slopes greater than 15 degrees.

• Do not mow near drop–offs, ditches, steep banks or

water. Wheels dropping over edges can cause rollovers,

which may result in serious injury, death or drowning.

• Do not mow slopes when grass is wet. Slippery

conditions reduce traction and could cause sliding and

loss of control.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

• Be sure all drives are in neutral and parking brake is

engaged before starting engine. Start the engine only from the operator’s position.

• Never raise deck with the blades running.

• Never operate without the PTO shield, or other guards

securely in place. Be sure all interlocks are functioning properly.

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or overspeed

the engine.

• Stop on level ground, lower implements, disengage

drives, engage parking brake, shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking objects

or if an abnormal vibration occurs. Make necessary repairs before resuming operations.

• Keep hands and feet away from the cutting units.

• Never carry passengers and keep pets and bystanders

away.

• Be alert, slow down and use caution when making

turns. Look behind and to the side before changing directions.

• Slow down and use caution when crossing roads and

sidewalks. Stop blades if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs.

• Use extreme care when loading or unloading the

machine into a trailer or truck.

• Do not make sudden turns or rapid speed changes.

• Use a walk behind mower and/or a hand trimmer near

drop–offs, ditches, steep banks or water.

• Reduce speed and use extreme caution on slopes.

• Remove or mark obstacles such as rocks, tree limbs,

etc. from the mowing area. Tall grass can hide

obstacles.

• Watch for ditches, holes, rocks, dips, and rises that

change the operating angle, as rough terrain could

overturn the machine.

• Avoid sudden starts when mowing uphill because the

mower may tip backwards.

• Be aware that loss of traction may occur going

downhill. Weight transfer to the front wheels may cause

drive wheels to slip and cause loss of braking and

steering.

• Always avoid sudden starting or stopping on a slope. If

tires lose traction, disengage the blades and proceed

slowly off the slope.

• Follow the manufacturer’s recommendations for wheel

weights or counterweights to improve stability.

• Use extreme care with grass catchers or other

attachments. These can change the stability of the

machine and cause loss of control.

Using the Rollover Protection System (ROPS)

• Keep the roll bar in the raised and locked position and

use the seat belt when operating the machine.

• Be certain that the seat belt can be released quickly in

the event of an emergency.

• Be aware there is no rollover protection when the roll

bar is down.

• Check the area to be mowed and never fold the ROPS

in areas where there are slopes, drop offs or water.

Page 5

• Lower the rollbar only when absolutely necessary. Do

not wear the seat belt with the roll bar folded down.

• Check carefully for overhead clearances (i.e. branches,

doorways, electrical wires) before driving under any objects and do not contact them.

Maintenance and storage

• Disengage drives, lower implement, set parking brake,

stop engine and remove key or disconnect spark plug wire. Wait for all movement to stop before adjusting, cleaning or repairing.

• Clean grass and debris from cutting units, drives,

mufflers, and engine to help prevent fires. Clean up oil or fuel spillage.

• Let engine cool before storing and do not store near

flame.

• Shut off fuel while storing or transporting. Do not store

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored

energy.

• Disconnect battery or remove spark plug wire before

making any repairs. Disconnect the negative terminal first and the positive last. Reconnect positive first and negative last.

• Use care when checking blades. Wrap the blade(s) or

wear gloves, and use caution when servicing them. Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before connecting or disconnecting from battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

• Use only Toro-approved attachments. Warranty may be

voided if used with unapproved attachments.

Page 6

Page 7

Slope Chart

Page 8

Page 9

Safety and Instruction Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost.

1-643401

1–653140

1–653147

1-633818

43-8480

1-523552

66-1340

Page 10

67-5360

93-1122

65–2690

98-4387

1. Warning—wear hearing protection.

98-5954

93-7818

1. Warning—read the torquing the blade bolt/nut to 115–149 N⋅m (85–110 ft-lb).

Operator’s Manual

for instructions on

98-3798

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

103–0262

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

Manual.

Operator’s

distance from the battery.

Page 11

104-8569

103–2644

99-3943

1. Engine

1. Contains lead; do not discard.

2. Recycle

3. Wear eye protection; explosive gases can cause blindness and other injuries

4. No sparks, flame, or smoking

5. Sulfuric acid can cause blindness or severe burns.

104-4164

6. Flush eyes immediately with water and get medical help fast.

7. Maximum fill line

8. Minimum fill line

9. Instructions for activating the battery

Page 12

106-6586

103-1997

107-2102

99-3924

Page 13

107-2112

Page 14

Gasoline and Oil

Recommended Gasoline

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

Important Never use methanol, gasoline containing

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

Danger

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

• Fill the fuel tank outdoors, in an open area,

when the engine is cold. Wipe up any gasoline that spills.

• Never fill the fuel tank inside an enclosed trailer.

• Do not fill the fuel tank completely full. Add

gasoline to the fuel tank until the level is 1/4 to 1/2 inch (6 to 13 mm) below the bottom of the filler neck. This empty space in the tank allows gasoline to expand.

• Never smoke when handling gasoline, and stay

away from an open flame or where gasoline fumes may be ignited by a spark.

• Store gasoline in an approved container and

keep it out of the reach of children. Never buy more than a 30-day supply of gasoline.

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

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

• When practical, remove gas–powered

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

• If this is not possible, then refuel such

equipment on a truck or trailer from a portable container, rather than from a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, keep

the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Do not operate without entire exhaust system in

place and in proper working condition.

Warning

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

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

• Keeps gasoline fresh during storage of 90 days or less.

For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system,

which causes hard starting

Important Do not use fuel additives containing

methanol or ethanol. Add the correct amount of gas stabilizer/conditioner to the

gas. Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Filling the Fuel Tank

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

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

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

3. Install fuel tank caps securely. Wipe up any gasoline

that may have spilled.

Checking the Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 29.

Page 15

Operation

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

Using the Rollover Protection

System (ROPS)

Warning

To avoid injury or death from rollover: keep the roll bar in the raised locked position and use the seat belt.

Ensure that the rear part of the seat is secured with the seat latch.

Warning

There is no rollover protection when the roll bar is in the down position.

• Lower the roll bar only when absolutely

necessary.

• Do not wear the seat belt when the roll bar is in

the down position.

• Drive slowly and carefully.

• Raise the roll bar as soon as clearance permits.

• Check carefully for overhead clearances (i.e.

branches, doorways, electrical wires) before driving under any objects and do not contact them.

m–6836

Figure 2

1. Full down position 2. Down position with bagger installed

Important Always use the seat belt with the roll bar in

the raised position.

Important Ensure that the rear part of the seat is

secured with the seat latch.

5. To raise the roll bar, remove the hairpin cotter pins and

remove the two pins (Fig. 3).

6. Raise the roll bar to the upright position and install the

two pins and secure them with the hairpin cotter pins (Fig. 3).

Important Lower the roll bar only when absolutely

necessary.

1. To lower the roll bar, loosen the front handles (Fig. 4).

2. Remove the hairpin cotter pins and remove the two pins

(Fig. 3).

3. Lower the the roll bar to the down position. There are

two down positions. See Figure 2 for the positions.

4. Install the two pins and secure them with the hairpin

cotter pins (Fig. 3).

1. Roll bar

2. Raised position

m–6893

Figure 3

3. Pin

4. Hairpin cotter pin

Page 16

7. Tighten the front handles against the center roll bar ends

(Fig. 3).

m–6897

Figure 4

1. Front handle

Think Safety First

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

Danger

Operating on wet grass or steep slopes can cause sliding and loss of control.

Wheels dropping over edges can cause rollovers, which may result in serious injury, death or drowning.

There is no rollover protection when the roll bar is down.

Always keep the roll bar in the raised and locked position and use the seat belt.

m–6478

Figure 5

1. Safe Zone—use the Z Master here on slopes less than 15 degrees or flat areas.

2. Use walk behind mower and/or hand trimmer near drop–offs and water.

3. Water

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

Caution

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

Wear hearing protection when operating this machine.

Read and follow the rollover protection instructions and warnings.

To avoid loss of control and possibility of rollover:

• Do not operate near drop–offs or near water.

• Do not operate on slopes greater than

15 degrees.

• Reduce speed and use extreme caution on slopes.

• Avoid sudden turns or rapid speed changes.

Figure 6

1. Warning—wear hearing protection.

Page 17

Controls

Become familiar with all the controls (Fig. 7) before you start the engine and operate the machine.

The unit has two fuel tanks. One tank is on the left side and one on the right side. Each tank connects to the fuel shut off valve in the control panel. From there a common fuel line leads to the engine (Fig. 9).

To use the left side fuel tank rotate the fuel shut off valve to the LH, lefthand location. To use the right side fuel tank rotate the fuel shut off valve to the RH, righthand location (Fig. 9).

Close fuel shut off valve before transporting or storing machine.

Figure 9

1. Shut-off valve

m–4200

Figure 7

1. Ignition switch

2. Motion control lever

3. Parking brake lever

4. Throttle

5. Choke

6. Power take off (PTO)

7. Height-of-cut lever

8. Fuel cap

9. Hourmeter

10. Fuel shut-off valve

Using the Hour Meter

The hour meter records the number of hours the engine has operated. It operates when the engine is running. Use these times for scheduling regular maintenance.

m–4202

Figure 8

1. Hour meter

Operating the Parking Brake

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

Important Do not park on slopes unless the wheels are

chocked or blocked.

Setting the Parking Brake

1. Move the motion control levers (Fig. 10) out to the

neutral lock position.

2. Pull back and up on the parking brake lever to set the

parking brake (Fig. 10). The parking brake lever should stay firmly in the Engaged position.

Releasing the Parking Brake

Push forward and down on the parking brake lever to release the parking brake (Fig. 10). The parking brake is disengaged.

Switching the Fuel Tanks

The fuel shut off valve is located under the seat.

Page 18

m–4121

Figure 10

1. Parking brake—On 2. Parking brake—Off

Starting and Stopping the Engine

Starting the Engine

1. Sit down on the seat and move the motion controls to

the neutral locked position.

2. Set the parking brake; refer to Setting the Parking

Brake, page 17.

3. Move the PTO (power take off) to Off (Fig. 11).

4. Move the choke control to the On position before

starting a cold engine (Fig. 12).

Note: A warm or hot engine may require choking. After the engine starts, move the choke control to the Off position.

5. Move the throttle control to the Fast position before

starting a cold engine (Fig. 13).

Figure 11

1. PTO—On

2. PTO—Off

Figure 13

1. Fast

2. Slow

m–4201

m–2720

m–2719

Figure 12

1. Choke—On

2. Choke—Off

M–4268

Figure 14

1. Off

2. Run

3. Start

6. Turn the ignition key to Start to energize the starter.

When the engine starts, release the key (Fig. 14).

Important Do not engage the starter for more than

10 seconds at a time. If the engine fails to start, allow a 30 second cool-down period between attempts. Failure to follow these instructions can burn out the starter motor.

7. After the engine starts, move the choke to Off (Fig. 12).

If the engine stalls or hesitates, move the choke back to On for a few seconds. Then move the throttle lever to the desired setting. Repeat this as required.

Stopping the Engine

1. Push the PTO to off (Fig. 13).

2. Move the throttle lever midway between the slow and

fast positions (Fig. 13).

3. Let the engine idle for 60 seconds (Fig. 14).

4. Turn the ignition key to off (Fig. 14).

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

someone accidentally starting the machine before transporting or storing machine.

6. Close fuel shut off valve, on front panel before

transporting or storing machine.

Page 19

Important Make sure that the fuel shut off valve is

closed before transporting or storing the machine, as fuel leakage may occur. Set the parking brake before transporting. Make sure to remove the key as the fuel pump may run and cause the battery to lose charge.

Caution

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

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

Operating the Power Take Off (PTO)

The Safety Interlock System

Caution

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

• You are sitting on the seat.

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

Engaging the PTO

1. While seated in the seat, release the pressure on the

traction control levers and place in neutral.

2. Place the throttle into the fast position.

3. Pull out on the power take off (PTO) switch to engage

(Fig. 15).

m–4201

Figure 15

1. PTO—Off 2. PTO—On

• The parking brake is engaged.

• The power take off (PTO) is disengaged.

• The motion control levers are in the neutral lock

position.

The safety interlock system also is designed to stop the engine when the traction controls are moved with the parking brake on engaged or if you rise from the seat when the PTO is on or engaged.

Testing the Safety Interlock System

Test the safety interlock system before you use the machine each time. If the safety system does not operate as described below, have an Authorized Service Dealer repair the safety system immediately.

1. Sitting on the seat, engage the parking brake, and move

the PTO On. Try starting the engine; the engine should not crank.

2. Sitting on the seat, engage the parking brake, and move

the PTO to Off. Move either motion control lever (forward or reverse). Try starting the engine; the engine should not crank. Repeat for the other motion control lever.

Disengaging the PTO

To disengage, push the PTO switch to the Off position (Fig. 15).

3. Sitting on the seat, engage the parking brake, move the

PTO to Off, and lock the motion control levers in neutral. Now start the engine. While the engine is running, release the parking brake, engage the PTO and rise slightly from the seat; the engine should stop.

4. Sitting on the seat, engage the parking brake, move the

PTO to Off, and lock the motion control levers in neutral. Now start the engine. While the engine is running, center the motion controls and move (forward or reverse); the engine should stop.

Page 20

5. Sitting on the seat, disengage the parking brake, move

the PTO switch to Off, and move the motion control levers to the neutral lock position. Try starting the engine; the engine should not crank.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in RPM (revolutions per minute). Place the throttle control in the Fast position for best performance. Always operate in the full throttle position.

Caution

Machine can spin very rapidly. Operator may lose control of machine and cause personal injury or damage to machine.

• Use caution when making turns.

• Slow the machine down before making sharp

turns.

Figure 16

1. Motion control lever—neutral lock position

m–2715

2. Center unlock position

3. Forward

4. Backward

Driving Backward

1. Move the levers to the center, unlocked position.

2. To go backward, slowly pull the motion control levers

rearward (Fig. 16).

Driving Forward

1. Release the parking brake; refer to Releasing the

Parking Brake, page 17.

2. Move the levers to the center, unlocked position.

3. To go forward, slowly push the motion control levers

forward (Fig. 16).

Note: The engine will kill if the traction control levers are moved with the parking brake engaged.

To go straight, apply equal pressure to both motion control levers (Fig. 16).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 16).

The farther you move the traction control levers in either direction, the faster the machine will move in that direction.

To stop, pull the motion control levers to neutral.

To go straight, apply equal pressure to both motion control levers (Fig. 16).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 16).

To stop, push the motion control levers to neutral.

Stopping the Machine

To stop the machine, move the traction control levers to neutral and separate to lock, disengage the power take off (PTO), and turn the ignition key to Off to stop the engine. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 17. Remember to remove the key from the ignition switch.

Caution

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

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

Page 21

Adjusting the Height-of-Cut

The height-of-cut is adjusted from 1-1/2 to 4-1/2 inch (38 to 114 mm) in 1/4 inch (6 mm) increments by relocating the clevis pin in different hole locations.

1. Raise the height-of-cut lever to the transport position

(also the 4-1/2 inch [114 mm] cutting height position) (Fig. 17).

2. To adjust, remove the hairpin cotter and clevis pin from

the height-of-cut bracket (Fig. 17).

3. Select the hole in the height-of-cut bracket

corresponding to the height-of-cut desired, and insert the clevis pin (Fig. 17).

4. Secure the clevis pin with the hairpin cotter (Fig. 17).

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

moving parts to stop before leaving the operating position.

1. Disengage the power take off (PTO) and turn the

ignition key to Off. Move the control levers to the neutral locked position and apply the parking brake. Remove the key.

2. After adjusting the height-of-cut, remove the nut and

washer while holding the stud with a wrench (Fig. 18).

Note: Do not remove the wheel nut and washer (Fig. 18).

3. Select a hole so that the gage wheel is positioned to the

nearest corresponding height-of-cut desired (Fig. 18).

4. Reinstall the stud nut and washer (Fig. 18).

5. Repeat the adjustment on the other gage wheels.

m–4122

Figure 17

1. Height-of-cut lever

2. Clevis pin

3. Hairpin cotter

5. Lower the height-of-cut lever onto the clevis pin

(Fig. 17).

Adjusting the Anti-Scalp Rollers

Whenever you change the height-of-cut it is recommended to adjust the height of the anti-scalp rollers.

Adjusting the Outer Rollers

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

m–4167

Figure 18

1. Gage wheel

2. Stud

3. Washer

4. Nut

5. Wheel nut and washer. Do not remove.

Adjusting the Center Rollers

1. Disengage the power take off (PTO) and turn the

ignition key to Off. Move the control levers to the neutral locked position and apply the parking brake.

2. After adjusting the height-of-cut, remove the bolt and

nut (Fig. 19).

3. Select a hole so that the gage wheel is positioned to the

nearest corresponding height-of-cut desired (Fig. 19).

Note: Do not adjust the rollers to support the deck.

Page 22

4. Reinstall the bolt, center rollers, and nut (Fig. 19).

Important Do not rotate the by–pass valves more than

1 turn. This prevents the valves from coming out of the body and causing fluid to run out.

Figure 19

1. Center rollers and spacer

2. Nut

3. Bolt

m–4124

Positioning the Seat

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

1. To adjust, move the lever sideways to unlock seat

(Fig. 20).

2. Slide the seat to the desired position and release the

lever to lock the seat in position.

Changing to Machine Operation

Turn the by-pass valves in to operate (Fig. 21).

Note: Do not over tighten the by–pass valves. Note: The machine will not drive unless the by-pass valves

are turned in.

m–6279

Figure 21

1. By-pass valve

Operating with Side Discharge

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

m–3655

Figure 20

1. Adjustment lever

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

To Push the Machine

1. Disengage the power take off (PTO) and turn the

ignition key to Off.

2. Rotate the by-pass valves counterclockwise 1 turn to

push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 21).

Danger

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

• Never remove the grass deflector from the

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

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

blades unless you move the power take off (PTO) to Off and rotate the ignition key to Off. Also remove the key and pull the wire off the spark plug(s).

• Make sure the grass deflector is in the down

position.

Page 23

Transporting the Machine

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

To transport the machine:

• Lock the brake and block the wheels.

• Securely fasten the machine to the trailer or truck with

straps, chains, cable, or ropes.

• Secure a trailer to the towing vehicle with safety chains.

Warning

Driving on street or roadway without turn signals, lights, reflective markings, or a slow moving vehicle emblem is dangerous and can lead to accidents causing personal injury.

Do not drive machine on a public street or roadway.

Warning

Loading a unit onto a trailer or truck increases the possibility of backward tip–over and could cause serious injury or death.

• Use extreme caution when operating a unit on a

ramp.

• Use only a single, full width ramp; DO NOT use

individual ramps for each side of the unit.

• If individual ramps must be used, use enough

ramps to create an unbroken ramp surface wider than the unit.

• Do not exceed a 15 degree angle between ramp

and ground or between ramp and trailer or truck.

• Avoid sudden acceleration while driving unit up

a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing unit

down a ramp to avoid tipping backward.

Loading Machines

Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Fig. 22). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

The ramp should be long enough so that the angles do not exceed 15 degrees (Fig. 22). A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck. Steeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

Important Do Not attempt to turn the unit while on the

ramp; you may lose control and drive off the side. Avoid sudden acceleration when driving up a ramp and

sudden deceleration when backing down a ramp. Both maneuvers can cause the unit to tip backward.

m–6841

1. Trailer

2. Full width ramp

3. Not greater than 15 degrees

Figure 22

4. Full width ramp—side view

Page 24

Tips for Mowing Grass

Fast Throttle Setting

For best mowing and maximum air circulation, operate the engine at fast. Air is required to thoroughly cut grass clippings, so do not set the height-of-cut so low as to totally surround the mower by uncut grass. Always try to have one side of the mower free from uncut grass, which allows air to be drawn into the mower.

Cutting a Lawn for the First Time

Cut grass slightly longer than normal to ensure that the cutting height of the mower does not scalp any uneven ground. However, the cutting height used in the past is generally the best one to use. When cutting grass longer than 6 inches (15 cm) tall, you may want to cut the lawn twice to ensure an acceptable quality of cut.

Cut 1/3 of the Grass Blade

It is best to cut only about 1/3 of the grass blade. Cutting more than that is not recommended unless grass is sparse, or it is late fall when grass grows more slowly.

Mowing Direction

Alternate mowing direction to keep the grass standing straight. This also helps disperse clippings which enhances decomposition and fertilization.

Long Grass

If the grass is ever allowed to grow slightly longer than normal, or if it contains a high degree of moisture, raise the cutting height higher than usual and cut the grass at this setting. Then cut the grass again using the lower, normal setting.

When Stopping

If the machine’s forward motion must be stopped while mowing, a clump of grass clippings may drop onto your lawn. To avoid this, move onto a previously cut area with the blades engaged.

Keep the Underside of the Mower Clean

Clean clippings and dirt from the underside of the mower after each use. If grass and dirt build up inside the mower, cutting quality will eventually become unsatisfactory.

Blade Maintenance

Maintain a sharp blade throughout the cutting season because a sharp blade cuts cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease. Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade.

Mow at Correct Intervals

Normally, mow every four days. But remember, grass grows at different rates at different times. So to maintain the same cutting height, which is a good practice, mow more often in early spring. As the grass growth rate slows in mid summer, mow less frequently. If you cannot mow for an extended period, first mow at a high cutting height; then mow again two days later at a lower height setting.

Cutting Speed

To improve cut quality, use a slower ground speed.

Avoid Cutting Too Low

If the cutting width of the mower is wider than the mower you previously used, raise the cutting height to ensure that uneven turf is not cut too short.

Page 25

Maintenance

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

Recommended Maintenance Schedule

Maintenance Service

Interval

Maintenance Procedure

• Check hydraulic fluid level

After First 5 Hours

• Change engine oil

• Change hydraulic filter

• Check engine oil level

Each Use

• Check safety system

• Clean engine air intake

• Clean mower housing

Every 5 Hours

• Check cutting blades

• Grease blade spindle bearings

• Check hydraulic fluid level

• Grease mower support and push arms

• Grease brake lever

Every 25 Hours

• Oil linkage bushings

• Service foam air cleaner

• Check battery electrolyte

• Check tire pressure

• Grease both idler pulley pivots

Every 40 Hours • Grease front tires

Every 50 Hours • Check belts for wear/cracks

• Change engine oil

Every 100 Hours

• Service paper air cleaner

• Check spark plug(s)

• Check hydraulic lines

• Change hydraulic filter

• Change oil filter

Every 200 Hours

• Replace paper air cleaner

• Replace fuel filter

• Grease brake lever pivot

Every 300 Hours • Clean cooling system

Every 500 Hours or at

Storage

• Adjust and grease caster pivot

• Adjust wheel hub slotted nut

• Perform all maintenance procedures listed above before storage

Before Storage

• Drain gasoline

• Charge battery, disconnect cables

• Paint chipped surfaces

More often in dusty, dirty conditions

Page 26

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

Caution

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

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

Servicing the Cutting Blades

Maintain sharp blades throughout the cutting season because sharp blades cut cleanly without tearing or shredding the grass blades. Tearing and shredding turns grass brown at the edges, which slows growth and increases the chance of disease.

Check the cutter blades daily for sharpness, and for any wear or damage. File down any nicks and sharpen the blades as necessary. If a blade is damaged or worn, replace it immediately with a genuine Toro replacement blade. For convenient sharpening and replacement, you may want to keep extra blades on hand.

Danger

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

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

2. Inspect the blades, especially the curved area (Fig. 23).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 23), immediately install a new blade.

m–151

1. Cutting edge

2. Curved area

Figure 23

3. Wear/slot forming

Checking for Bent Blades

Before Inspecting or Servicing the Blades

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

Inspecting the Blades

1. Inspect the cutting edges (Fig. 23). If the edges are not

sharp or have nicks, remove and sharpen the blades; refer to Sharpening the Blades, page 27.

1. Rotate the blades until the ends face forward and

backward (Fig. 24). Measure from a level surface to the cutting edge of the blades (Fig. 25). Note this dimension.

Page 27

Front

Warning

Contact with sharp blade can cause serious injury. Wear gloves or wrap sharp edges of the blade with

a rag.

m–1078

Figure 24

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 25

2. Rotate the opposite ends of the blades forward.

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

blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 3 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced; refer to Removing the Blades and Installing the Blades, page 28.

Figure 26

1. Sail area of blade

2. Blade

3. Spring disk

4. Blade bolt

Sharpening the Blades

Warning

When sharpening blade, pieces of blade could be thrown and cause serious injury.

Wear proper eye protection when sharpening blade.

m–4318

Warning

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

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

Removing the Blades

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

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, spring disk, and blade from the spindle shaft (Fig. 26).

1. Use a file to sharpen the cutting edge at both ends of the

blade (Fig. 27). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 27

1. Sharpen at original angle

2. Check the balance of the blade by putting it on a blade

balancer (Fig. 28). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off of the end of the sail area only (Fig. 26). Repeat this procedure until the blade is balanced.

Page 28

Figure 28

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 26).

m–1855

Important The curved part of the blade must be

pointing upward toward the inside of the mower to ensure proper cutting.

2. Install the flat washer, lock washer, and blade bolt

(Fig. 26). Torque the blade bolt to 85–110 ft-lb (115–150 N⋅m).

Cleaning the Cooling System

Clean the air intake screen from grass and debris before each use.

Clean the cooling fins and engine shrouds every 300 hours or yearly, which ever comes first.

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Remove the air intake screen, air cleaner cover, fan

housing, and bolts (Fig. 29).

4. Clean debris and grass from the engine shrouds and

cooling fins.

5. Reinstall the air intake screen, air cleaner cover, fan

housing, and bolts (Fig. 29). Torque the bolts to 4.3 ft-lb (5.8 N⋅m).

m–4369

Figure 29

1. Air intake screen

2. Fan housing

3. Air cleaner cover

4. M6 x 10mm bolt

5. M6 x 12mm bolt

6. M6 x 20mm bolt

Servicing the Air Cleaner

Primary Filter: Check and/or replace after every 200 operating hours or more often in dusty conditions.

Safety Filter: Replace after every 600 operating hours. Note: Check the filters more frequently if operating

conditions are extremely dusty or sandy.

Removing the Filters

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Release the latches on the air cleaner and pull the air

cleaner cover off of the air cleaner body (Fig. 30).

4. Clean the inside of the air cleaner cover with

compressed air.

5. Gently slide the primary filter out of the air cleaner

body (Fig. 30). Avoid knocking the filter into the side of the body.

Page 29

6. Remove the safety filter only if you intend to replace it.

Important Never attempt to clean the safety filter. If

the safety filter is dirty, then the primary filter is damaged and you should replace both filters.

3. Carefully slide the primary filter over the safety filter

(Fig. 30). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

Important Do not press on the soft inside area of the

filter.

7. Inspect the primary filter for damage by looking into the filter while shining a bright light on the outside of the filter. Holes in the filter will appear as bright spots. If the filter is damaged discard it.

m–4815

Figure 30

1. Latches

2. Air cleaner cover

3. Air filter body

4. Primary filter

5. Safety filter

Servicing the Primary Filter

4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 30).

Servicing the Engine Oil

Change the oil:

• After the first 8 operating hours.

• After every 100 operating hours.

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

Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity:

• 51 oz. (1.5 l) (When the oil filter is not removed)

• 57 oz. (1.7 l) (When the oil filter is removed)

Viscosity: See the table below.

USE THESE SAE VISCOSITY OILS

Check and/or replace it after 200 operating hours. If the primary filter is dirty, bent, or damaged then replace

the filter. Do not clean the primary filter.

Servicing the Safety Filter

Replace it after 600 operating hours.

Important Never attempt to clean the safety filter. If

the safety filter is dirty, then the primary filter is damaged and you should replace both filters.

Installing the Filters

Important To prevent engine damage, always operate

the engine with both air filters and cover installed.

1. If installing new filters, check each filter for shipping

damage. Do not use a damaged filter.

2. If the safety filter is being replaced, carefully slide it

into the filter body (Fig. 30).

m–4292

Checking the Oil Level

Check the engine oil level daily.

1. Park the machine on a level surface.

2. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

4. Clean around the oil dipstick (Fig. 31) so that dirt cannot fall into the filler hole and damage the engine.

5. Unscrew the oil dipstick and wipe the end clean (Fig. 31).

Page 30

6. Slide the oil dipstick fully into the filler tube. Do not

thread it onto the tube (Fig. 31). Pull the dipstick out and look at the end. If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark.

Important Do not overfill the crankcase with oil

because the engine may be damaged. Do not run engine with oil below the low mark because the engine may be damaged.

m–5625

Figure 32

1. Oil drain valve

6. Slowly pour approximately 80% of the specified oil into

the filler cap (Fig. 31). Refer to Servicing the Engine Oil, page 29.

7. Check the oil level; refer to Checking the Oil Level,

page 29.

m–4368

Figure 31

1. Oil dipstick

2. Filler tube

3. Dipstick end

Changing the Oil

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

warms the oil so that it drains better.

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

than the opposite side to ensure that the oil drains completely. Disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key.

3. Place a pan below the oil drain. Use either a flat screw

driver, 3/8 inch wrench, or 10 mm wrench to open the valve (Fig. 32).

4. Rotate the valve end clockwise to close the valve.

Rotate the valve end counterclockwise to open the valve (Fig. 32).

5. When the oil has drained completely, close the drain

valve (Fig. 32).

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

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

Changing the Oil Filter

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

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

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

page 30.

2. Remove the old filter (Fig. 33).

3. Apply a thin coat of new oil to the rubber gasket on the

replacement filter (Fig. 33).

m–4288

Figure 33

1. Oil filter 2. Adapter

4. Install the replacement oil filter to the adapter. Turn the

oil filter clockwise until the rubber gasket contacts the filter adapter; then tighten the filter an additional 3/4 turn (Fig. 33).

Page 31

5. Fill the crankcase with the proper type of new oil; refer

to Servicing the Engine Oil, page 29.

Important Always replace the spark plug(s) when it

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

Servicing the Spark Plug

Check the spark plug(s) after every 100 operating hours. Make sure that the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: NGK BPR5ES (or equivalent) Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plug(s)

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Pull the wire(s) off of the spark plug(s) (Fig. 34). Clean

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

4. Remove the spark plug(s).

2. Clean the electrode by scraping or with a wire brush to

remove carbon deposits and wetness.

3. Check the gap between the center and side electrodes (Fig. 35). Bend the side electrode (Fig. 35) if the gap is not correct.

0.030 inch (0.76 mm)

m–3215

Figure 35

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

m–4294

Figure 34

1. Spark plug wire installed 2. Spark plug

Checking the Spark Plug

Clean or replace the spark plug and set the gap every 100 hours.

1. Look at the center of the spark plug(s) (Fig. 35). If you

see light brown or gray on the insulator, the engine is operating properly. A black coating on the insulator usually means the air cleaner is dirty.

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

2. Tighten the spark plug(s) to 16 ft-lb (22 N⋅m).

3. Push the wire(s) onto the spark plug(s) (Fig. 34).

Replacing the Fuel Filter

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

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

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

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

3. Allow the machine to cool down.

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

moving parts to stop before leaving the operating position.

5. Close the fuel shut-off valve on the console.

6. Squeeze the ends of the hose clamps together and slide

them away from the filter (Fig. 36).

7. Remove the filter from the fuel lines.

Page 32

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

the filter (Fig. 37).

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

9. Open the fuel shut-off valve on the console.

M–4294

Figure 36

1. Filter 2. Hose clamp

Draining the Fuel Tank

Danger

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

• Drain gasoline from the fuel tank when the

engine is cold. Do this outdoors in an open area. Wipe up any gasoline that spills.

• Never smoke when draining gasoline, and stay

away from an open flame or where a spark may ignite the gasoline fumes.

1. Park the machine on a level surface to ensure that the

fuel tanks drain completely. Then disengage the power take off (PTO), set the parking brake, stop the engine, and remove the key.

2. Close the fuel shut-off valve (Fig. 37).

3. Loosen the hose clamp at the fuel filter and slide it up

the fuel line away from the fuel filter (Fig. 37).

4. Pull the fuel line off of the fuel filter (Fig. 37).

6. Install the fuel line onto the fuel filter. Slide the hose

clamp close to the fuel filter to secure the fuel line (Fig. 37).

1. Fuel shut-off valve

2. Fuel filter

Figure 37

3. Hose clamp

4. Fuel line

M–4294

Greasing and Lubrication

Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 38). Grease more frequently

when operating conditions are extremely dusty or sandy. Grease with No. 2 general purpose lithium base or

molybdenum base grease.

How to Grease

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Clean the grease fittings with a rag. Make sure to scrape

any paint off of the front of the fitting(s).

4. Connect a grease gun to the fitting. Pump grease into

the fittings until grease begins to ooze out of the bearings.

5. Open the fuel shut-off valve for the left and right tanks.

Allow gasoline to drain into a gas can or drain pan (Fig. 37).

5. Wipe up any excess grease.

Page 33

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 38).

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

3. Grease the fittings on the three spindle bearings (Fig. 39).

4. Grease the idler pulley pivot (Fig. 39).

5. Grease the fittings on the push arms (Fig. 39).

Figure 38

Greasing the Front Caster Pivots

Lubricate the front caster pivots once a year.

1. Remove the dust cap and adjust the caster pivots. Keep

dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing, page 38.

2. Remove the hex plug. Thread a grease zerk into hole.

3. Pump grease into zerk until it oozes out around top

bearing.

4. Remove grease zerk in hole. Reinstall hex plug and cap.

Greasing the Bearings

The cutting unit must be lubricated regularly; refer to the Recommended Maintenance Schedule, page 25. Grease with No. 2 general purpose lithium base or molybdenum base grease.

M–4159

Figure 39

Where to Add Light Oil or Spray Lubrication

Lubricate the machine in the following areas with spray type lubricant or light oil. Lubricate every 160 hours.

• Seat switch actuator

• Brake handle pivot

• Brake rod bushings

• Motion control bronze bushings

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every

Page 34

50 operating hours or monthly, whichever occurs first (Fig. 40). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 13 psi (90 kPa) drive wheels and caster wheels

7. If required, add fluid to the hydraulic tank. Note: The fluid level should be to the top of the hot level

of the baffle, when the fluid is hot (Fig. 41).

8. Install cap on filler neck.

m–1872

Figure 40

1. Valve stem

Servicing the Hydraulic System

Checking the Hydraulic Fluid

Check the hydraulic fluid level:

• Before the engine is first started.

• After the first 8 operating hours.

• After every 25 operating hours.

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

Important Use oil specified or equivalent. Other fluids

could cause system damage. Hydraulic System Oil Capacity: 67 oz. (2.0 l) Note: There are two ways of checking the hydraulic oil.

One is when the oil is warm and one is when the oil is cold. The baffle inside the tank has two levels depending if the oil is warm or cold.

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

brake.

Figure 41

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it must

be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are

in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

m–5615

2. Clean area around filler neck of hydraulic tank

(Fig. 41).

3. Remove the cap from the filler neck. Look inside to

check if there is fluid in the reservoir (Fig. 41).

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

5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid. Refer to Starting and Stopping the Engine on page 18.

6. Recheck the fluid level while the fluid is warm. The fluid should be between cold and hot.

Page 35

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 8 operating hours.

• After every 200 operating hours.

Use summer filter above 32°F (0°C) Use winter filter below 32°F (0°C)

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

Important Do not substitute automotive oil filter or

severe hydraulic system damage may result.

3. Place drain pan under filter, remove the old filter and

wipe the filter adapter gasket surface clean (Fig. 42).

M–4763

Figure 42

1. Hydraulic filter

m–1256

Figure 43

1. Hydraulic filter

2. Gasket

3. Adapter

Bleeding the Hydraulic System

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

1. Raise rear of the machine so wheels are off the ground

and support with jack stands.

2. Start the engine and run at low idle speed. Engage the

lever and traction on one side and spin the wheel by hand.

3. When the wheel begins to spin on its own, keep it

engaged until wheel drives smoothly. (minimum 2 minutes)

4. Check hydraulic fluid level and add as required to

maintain proper level.

4. Apply a thin coat hydro fluid to the rubber gasket on the

replacement filter (Fig. 43).

5. Install the replacement hydraulic filter onto the filter

adapter. Do not tighten.

6. Fill the hydraulic tank with hydraulic fluid until the

fluid overflows the filter and then turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 43).

7. Clean up any spilled fluid.

8. Add fluid to the cold level of the baffle in the hydraulic

tank.

9. Start the engine and let it run for about two minutes to

purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 35.

10.Recheck the fluid level while the fluid is warm. The

fluid should be between cold and hot.

11. If required, add fluid to the hydraulic tank. Do not overfill.

5. Repeat this procedure on the opposite wheel.

Warning

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

• If hydraulic fluid is injected into the skin it must

be surgically removed within a few hours by a doctor familiar with this type of injury. Gangrene may result if this is not done.

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are

in good condition and all hydraulic connections and fittings are tight before applying pressure to hydraulic system.

Page 36

Checking the Hydraulic Lines

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

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

9. Apply slight rearward pressure on the motion control

lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 44).

Note: Keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position.

10.Tighten the nut and jam nut (Fig. 45).

Adjusting the Handle Neutral Position

If motion control levers do not align, or move easily into the console notch, adjustment is required. Adjust each lever, spring and rod separately.

Note: Motion control levers must be installed correctly. See Installing the Motion Control Levers in the Setup instructions.

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Tilt the seat forward.

4. Begin with either the left or right motion control lever.

5. Move lever to the neutral position but not locked

(Fig. 44).

6. Pull lever back until the clevis pin (on arm below pivot

shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig. 45).

7. Check where the control lever is relative to notch in

console (Fig. 44). It should be centered allowing lever to pivot outward to the neutral lock position.

11. Repeat on the opposite side of unit.

8 1

m–4118

Figure 45

1. Clevis pin in slot

2. Nut

3. Nut—Left hand thread

4. Adjustment bolt

5. Pump rod

6. Double nuts

7. Jam nut

8. Yoke

9. Ball joint

4 3

2 7

Figure 44

1. Neutral locked position

2. Control lever

3. Neutral potion

8. If adjustment is needed, loosen the nut and jam nut

against the yoke (Fig. 45).

m–6282

Page 37

Setting the Hydraulic Pump Neutral Position

3. Move motion control lever forward and reverse, then

back to neutral. Wheel must stop turning or slightly creep in reverse.

Note: Adjust handle neutral first. That has to be correct before the following adjustment can be made.

Danger

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

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Warning

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

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

This adjustment must be made with drive wheels turning.

4. Open throttle to fast. Make sure wheel remains stopped

or slightly creeps in reverse, adjust if necessary.

m–6283

Figure 46

1. Tracking knob

2. Pump rod

3. Adjustment bolt

1. Raise the frame and block up the machine so drive wheels can rotate freely.

2. Disconnect electrical connector from the seat safety switch. Temporarily install a jumper wire across terminals in the wiring harness connector.

3. Slide seat forward, disconnect prop rod and tilt seat fully forward.

Setting the Left–hand Hydraulic Pump Neutral Position

1. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 18.

Note: Motion control lever must be in neutral while making any adjustments.

2. Adjust pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 46).

Setting the Right–hand Hydraulic Pump Neutral Position

1. Loosen the locknuts at the ball joints on pump control

rod (Fig. 45).

2. Start the engine, open throttle 1/2 way and release

parking brake. Refer to Starting and Stopping the Engine, page 18.

Note: Motion control lever must be in neutral while making any adjustments.

Note: The front nut on the pump rod has left–hand threads.

3. Adjust pump rod length by rotating double nuts on rod,

in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 45).

4. Move motion control lever forward and reverse, then

back to neutral. Wheel must stop turning or slightly creep in reverse.

5. Open throttle to fast. Make sure wheel remains stopped

or slightly creeps in reverse, re-adjust if necessary.

Page 38

6. Tighten the nuts at the ball joints (Fig. 45).

Warning

Electrical system will not perform proper safety shut off with jumper wire installed.

• Remove jumper wire from wire harness

connector and plug connector into seat switch when adjustment is completed.

• Never operate this unit with jumper installed

and seat switch bypassed.

7. After both pump neutrals are set, shut off the machine.

8. Remove jumper wire from wire harness connector and

plug connector into seat switch.

9. Reinstall prop rod and lower the seat into position.

10.Remove the jack stands.

Adjusting the Tracking

The left–hand pump has a knob for adjusting the tracking.

Important Adjust the handle neutral and hydraulic

pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral on page 36 and Adjusting the Hydraulic Pump Neutral on page 37.

m–6280

Figure 47

1. Pump rod

2. Turn this way to track left

3. Tracking knob

4. Turn this way to track right

Adjusting the Caster Pivot Bearing

Check after every 500 operating hours or at storage, whichever occurs first.

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

1. Push both control levers forward the same distance.

2. Check if the machine pulls to one side. If it does, stop

the machine and set the parking brake.

3. Tip the seat up to access the tracking knob. Note: Determine the left and right sides of the machine

from the normal operating position.

4. To make the machine go right, turn the knob towards

the rightside of the machine. Refer to figure 47.

5. To make the machine go left, turn the knob towards the

leftside of the machine. Refer to figure 47.

6. Repeat adjustment until the tracking is correct.

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

moving parts to stop before leaving the operating position.

3. Remove the dust cap from the caster and tighten the

locknut (Fig. 48).

4. Tighten until the spring washers are flat and then back

off 1/4 turn to properly set the preload on the bearings (Fig. 48).

Important Make sure that the spring washers are

installed correctly as shown in Figure 48.

m–4640

Figure 48

1. Spring washers

2. Locknut

3. Dust cap

Page 39

Checking the Wheel Hub

Leveling the Mower at Three

Slotted Nut

Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft–lb (170 N⋅m).

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Remove the cotter pin.

4. Torque the slotted nut to 125 ft–lb (170 N⋅m) (Fig. 49).

5. Check the distance from the bottom of the slot in the

nut to the inside edge of the hole. Two threads or less should be showing (Fig. 49).

6. If more than two threads are showing, remove the nut

and install a washer between the hub and nut (Fig. 49).

7. Torque the slotted nut to 125 ft–lb (170 N⋅m) (Fig. 49).

8. Tighten the nut until the next set of slots line up with

the hole in the shaft (Fig. 49).

9. Install the cotter pin.

Positions

Important There are only three measuring positions

needed to level the mower.

Setting Up the Machine

1. Position mower on a flat surface.

2. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

4. Check tire pressure of all four tires. If needed, adjust to

13 psi (90 kPa)

5. Position the mower to the 3 inch (76 mm) height–of–cut

position.

6. Inspect the four chains. The chains need to have

tension.

Note: The rear chains need to be adjusted to the top of the slot, where attached to the mower.

• If one rear chain is loose, lower (loosen) the front

support arm on the same side. Refer to Adjusting the Front–to–Rear Mower Pitch on page 40.

• If one front chain is loose, raise (tighten) the front

support arm for that chain. Refer to Adjusting the Front–to–Rear Mower Pitch on page 40.

1. Slotted nut

2. Two threads or less showing

Figure 49

3. Hole in threaded shaft

4. Washer (if needed)

5. Slot

m–4638

Leveling the Mower Side–to–Side

1. Position the right blade front-to-rear (Fig. 50).

2. Measure the right blade at the B location (Fig. 50), from

a level surface to the cutting edge of the blade tip (Fig. 51).

3. Record this measurement. This measurement needs to

be 3–1/8 to 3–1/4 inches.

4. Position the left blade front-to-rear (Fig. 50).

5. Measure the left blade at the C location (Fig. 50), from

a level surface to the cutting edge of the blade tip (Fig. 51).

6. Record this measurement. This measurement needs to

be 3–1/8 to 3–1/4 inches.

Page 40

Front

9. Tighten the jam nut under the rear support arm and

tighten the bolt securing the chain to the rear support arm.

10.Adjust the opposite side if needed.

Adjusting the Front–to–Rear Mower Pitch

m–1078

Figure 50

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

m–2539

Figure 51

7. If the measurements at positions B or C are not correct,

loosen the bolt attaching the rear chain to the rear support arm (Fig. 52).

Front

1. Position the right blade front-to-rear (Fig. 53).

2. Measure the right blade at the A location (Fig. 53), from

a level surface to the cutting edge of the blade tip (Fig. 54).

3. Record this measurement.

4. Measure the right blade at the B location (Fig. 53), from

a level surface to the cutting edge of the blade tip (Fig. 54).

5. Record this measurement.

6. The mower blade should be a 1/4 to 3/8 inch (6 to 10 mm) lower at position A than at position B

(Fig. 53). If it is not correct, proceed to the following steps.

Front

m–1078

m–6920

Figure 52

1. Rear chain

2. Rear support arm

3. Bolt

4. Jam Nut

5. Adjustment bolt

6. Front swivel

7. Front support arm

8. Loosen the jam nut under the rear support arm and

adjust the adjustment bolt to get a measurement of 3–1/8 to 3–1/4 inches.

Note: It is recommended that both sides of the mower are adjusted the same distance.

Figure 53

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

m–2539

Figure 54

Note: Both of the front swivels need to be adjusted the same amount to maintain equal chain tension.

7. Loosen the front swivel jam nuts, at the front of the

right and left swivels, approximately a 1/2 inch (13 mm) (Fig. 55).

8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm) lower in front at A than in the rear at B (Fig. 55).

Page 41

9. Tighten both swivel jam nuts against the front swivel to

lock the height.

10.Check to make sure there is equal tension on the chains

and adjust again if needed.

Adjusting the Compression Spring

1. Raise the mower lift lever to the transport position

(Fig. 55).

2. Check the distance between the two large washers, it

needs to be 10–1/4 inches (260 mm) (Fig. 55).

3. Adjust this distance, by loosening the spring jam nut

and turning the nut in front of each spring (Fig. 55). Turning the nut clockwise will shorten the spring; counter–clockwise will lengthen the spring.

4. Lock the nut into position by tightening the spring jam

nut (Fig. 55).

Figure 56

1. Push arm

2. 15-5/16 inch (389 mm) nominal

3. Jam nut

4. Ball joint

Cleaning Under the Mower

Remove grass build up under the deck daily.

m–6273

m–6921

Front

Figure 55

1. 10–1/4 inch (260 mm) between the large washers

2. Front nut

3. Spring jam nut

4. Front swivel

5. Swivel jam nut

6. Lift nut

7. Front support arm

8. Large washer

Adjusting the Push Arms

If needed, adjust the push arms to increase or decrease the mower belt tension.

1. To adjust the push arms, loosen the jam nut and rotate the ball joint counterclockwise, one turn at a time.(Fig. 56).

2. Adjust each side the same amount. Each push arm should have a nominal length of 15-5/16 inch (389 mm) (Fig. 56).

Note: Increase the tension by lengthening the push arms and decrease the tension by shortening the push arms.

1. Position the mower on a flat surface.

2. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

4. Raise the deck to the transport position.

5. Lift the front of the unit and support the unit using jack

stands.

Danger

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

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Inspecting the Belts

Inspect all belts every 50 hours. Check belts for cracks, frayed edges, burn marks, or any

other damage. Replace damaged belts.

Replacing the Mower Belt

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

1. Disengage the PTO, move the motion control levers to

the neutral locked position and set the parking brake.

Page 42

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

moving parts to stop before leaving the operating position.

3. Remove the belt covers over the outside spindles.

4. Loosen the outer nut on the spring eye bolt (Fig. 57).

M–4197

Figure 57

Top View

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

5. Spring

6. 9-3/8 ± 1/8 inch (238 ± 3 mm)

7. Deck belt

5. Remove the belt. Start at the outside pulley and rotate

the belt off (Fig. 58).

Note: Dot not remove the spring from the eye bolt.

Caution

M–4159

Figure 58

Top View

1. Deck belt

2. Idler arm

3. Outside pulley

4. Spring

5. Idler pulley

Replacing the Pump Drive Belt

Check the pump drive belt for wear after every 50 hours of operation.

1. Remove the deck belt first; refer to Replacing the Deck

Belt, page 41.

2. Remove the bolt from the clutch strap and unplug the

clutch electrical wire (Fig. 59).

3. Pull the spring loaded idler to the side. Remove the

traction belt from the engine and hydro pump pulleys (Fig. 59).

Spring is under tension when installed and can cause personal injury.

Do not remove spring from spring eye bolt.

6. Remove spring loaded idler pulley (Fig. 57).

7. Route the new belt through the idler arm (Fig. 57).

8. Install the idler pulley and route the belt onto the other

pulleys (Fig. 58).

9. Tighten the outer nut on the spring eye bolt (Fig. 57). Note: Check the spring length. The spring should measure

9-3/8 ± 1/8 inch (238 ±3 mm) when installed. Adjust it if it does not (Fig. 57).

10.Install the belt covers over the outside spindles.

4. Install the new belt around the engine and hydro pump

pulleys (Fig. 59).

5. Pull the spring loaded idler to the side and align the

belt. Release pressure on the spring loaded idler (Fig. 59).

6. Install the deck belt.

Page 43

Figure 59

1. Clutch strap

2. Bolt

3. Clutch electrical wire

4. Belt

5. Idler

6. Clutch

Adjusting the Parking Brake

m–4119

1. Brake lever

2. Spring, 2-3/4 inch (74 mm)

3. Adjusting nuts

Figure 60

4. Collar on brake rod

5. 3/16–1/4 inch (5–7 mm)

6. Jam nut and yoke

7. Trunnion

M–4120

Check the parking brake for proper adjustment.

1. Disengage the brake lever (lever down).

2. Measure the length of the spring. The measurement

should be 2-3/4 inch (74 mm) between the washers (Fig. 60).

3. If an adjustment is necessary, loosen the jam nut below

the spring and tighten the nut directly below the yoke (Fig. 60). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on the opposite side of the unit.

4. Turn the nuts clockwise to shorten the spring length and

turn them counterclockwise to lengthen the spring.

5. Engage the parking brake, lever up.

6. Measure the distance between the trunnion roller and

the collar on the brake rod. The measurement should be 3/16–1/4 inch (5–7 mm) (Fig. 60).

7. If an adjustment is necessary, loosen the jam nut

directly below the yoke. Turn the bottom adjusting nuts until the correct measurement is obtained (Fig. 60). Tighten the jam nut at the yoke.

Servicing the Fuses

The electrical system is protected by fuses. It requires no maintenance; however, if a fuse blows, check the component/circuit for a malfunction or short.

Fuse: Main F1—20 amp, blade-type

Alternator F2—20 amp, blade-type

1. Raise the seat to gain access to the fuse holder (Fig. 61).

2. To replace the fuses, pull out on the fuse to remove it

(Fig. 61).

m–3653

Figure 61

1. Main—20 amp 2. Alternator—20 amp

Page 44

Servicing the Battery

Danger

Warning

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after

handling.

Checking Electrolyte Level

1. With the engine off, open the hood to locate the battery.

2. Look at the side of the battery. The electrolyte must be

up to the upper line (Fig. 62). Do not allow the electrolyte to get below the lower line (Fig. 62).

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

distilled water; refer to Adding Water to the Battery, page 45.

Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns.

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

Installing the Battery

1. Position battery in tray with terminal posts toward the

engine (Fig. 63).

2. First, install the positive (red) battery cable to positive

(+) battery terminal.

3. Then install negative battery cable and ground wire to

the negative (–) battery terminal.

4. Secure cables with 2 bolts (1/4 x 3/4 inch), 2 washers

(1/4 inch), and 2 locknuts (1/4 inch) (Fig. 63).

2 3

1. Filler caps

2. Upper line

5. Slide the red terminal boot onto the positive (red)

battery post.

6. Secure battery with J-bolts, hold down clamp and

2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 63).

m–5004

Figure 62

3. Lower line

Page 45

6 7

9 5

Warning

Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• Always Disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always Reconnect the positive (red) battery

cable before reconnecting the negative (black) cable.

Figure 63

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

5. Ground wire

6. Bolt, 1/4 x 3/4 inch

7. Washer, 1/4 inch

8. Locknut, 1/4 inch

9. Battery clamp

10. J-bolts

11. Wing nut, 1/4 inch

Removing the Battery

Warning

Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the machine.

• Do not allow metal tools to short between the

battery terminals and metal parts of the machine.

m–5598

1. Disengage the PTO, move the motion control levers to the neutral locked position and set the parking brake.

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

3. Tilt seat up.

4. First disconnect the negative battery cable and ground

wire from the negative (–) battery terminal (Fig. 63).

5. Slide the red terminal boot off the positive (red) battery terminal. Then remove positive (red) battery cable (Fig. 63).

6. Remove both wing nuts (1/4 inch) securing the battery clamp (Fig. 63).

7. Remove the battery.

Adding Water to the Battery

Note: Never fill the battery with distilled water while the battery installed in the machine. Electrolyte could be spilled on other parts and cause corrosion.

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

1. Remove the battery from the machine.

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

3. Remove the vent caps from the battery (Fig. 62).

4. Slowly pour distilled water into each battery cell until

the level is up to the upper line (Fig. 62) on the battery case.

Important Do not overfill the battery because

electrolyte (sulfuric acid) can cause severe corrosion and damage to the chassis.

Page 46

5. Wait five to ten minutes after filling the battery cells.

Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 62) on the battery case.

6. Reinstall battery vent caps.

Charging the Battery

Warning

Charging the battery produces gasses that can explode.

Never smoke near the battery and keep sparks and flames away from battery.

Important Always keep the battery fully charged

(1.265 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C).

1. Remove the battery from the chassis; refer to Removing

the Battery, page 45.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 44.

3. Make sure the filler caps are installed in battery. Charge

battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4–6 amps.

4. When the battery is fully charged, unplug the charger

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 64).

Replacing the Grass Deflector

Warning

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

• Never operate the lawn mower unless you install

a cover plate, a mulch plate, or a grass chute and catcher.

• Make sure the grass deflector is in the down

position.

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

the deflector to the pivot brackets (Fig. 65). Remove the damaged or worn grass deflector.

2. Place the spacer and spring onto the grass deflector.

Place the straight end of the spring behind the deck edge.

Note: Make sure that the straight end of the spring is installed behind the deck edge before installing the bolt as shown in Figure 65.

3. Install the bolt and nut. Place the hook end of the spring

around the grass deflector (Fig. 65).

Important The grass deflector must be able to lower

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

Figure 64

1. Positive Battery Post

2. Negative Battery Post

3. Red (+) Charger Lead

4. Black (–) Charger Lead

5. Install the battery in the machine and connect the

battery cables; refer to Installing the Battery on page 44.

Note: Do not run the machine with the battery disconnected, electrical damage may occur.

m–4970

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

m–5037

Figure 65

6. Grass deflector

7. Place behind deck edge before installing bolt

8. Hook end of spring

Page 47

Waste Disposal

Engine oil, hydraulic oil, and engine coolant are pollutants to the environment. Dispose of these according to your state and local regulations.

Caution

The mercury contained in the tilt switch is poisonous and exposure to mercury can cause severe illness.

Mercury Tilt Switch

The tilt switch on this unit is located under the seat. Tilt the seat up to gain access.

The tilt switch on this unit contains mercury, a hazardous material. Mercury that is outside a sealed container vaporizes at room temperature. The vapors are harmful. Mercury can be absorbed through the skin. Do not attempt to open or repair this switch.

A very small amount of mercury is contained in a hermetically sealed body. The steel switch is then potted in a hard epoxy in a plastic case. It is unlikely that the mercury will ever escape from the enclosure. These high performance and reliable inexpensive switches are recyclable.

Mercury is an important and beneficial compound but requires special care in handling and disposal. When used and managed properly, mercury is not a threat to people or the environment. This information is presented to users so that they are aware that these switches contain mercury and will apply sound disposal practices when these devices reach their normal end of life or are damaged.

Mercury Tilt Switch Disposal

• Never attempt to open or repair the tilt

switch.

• Avoid contact with the mercury.

Several states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures. The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled, or otherwise managed to ensure that it does not become part of solid waste or waters. Management and disposal practices must be within relevant federal, state, or local laws.

Return the switch to your Toro dealer if it is faulty and is being replaced or if the unit containing the switch is no longer operating and is being scrapped. If the switch is damaged or broken open, use extreme caution in handling. Call your local waste management authority or Toro Customer Service for instructions.

Page 48

Wiring Diagram

TAN

RED

PINK

WIRE COLOR CODES

BLUE

BROWN

BLACK

I A Y B

SW1

(IGNITION)

X S

WHITE

VIOLET

VIO

GREY

GREEN

YELLOW

PINK/BLACK

PK/BK

DK.GN

ORANGE

ORANGE/BLACK

DARK GREEN/WHITE DARK GREEN

OR/BK

DK.GN/W

DARK BLUE

DK.BU

LIGHT BLUE

LIGHT GREEN BLACK/RED

LT.GN BK/R

LT.BU

VIO

OR OR R

Y T

IGNITION

SPARK PLUG SPARK PLUG

25A

30A

MODULES

MAG

REG

VIO

HOUR

METER

FUEL

SOLINIOD

FUEL

–+

DK.BU

OIL

DK.BU

OIL

SWITCH

–+

GND

BATTERY

STARTER

DK.GN/W

235

–

GND

SOLINOID

OR/BKOR/BK

DK.GN

(KILL RELAY)

KEY SWITCH PN 88–9830

OFF NO CONNECTION

ON B I A AND X Y

START B I S

KEY SW

TERMINAL VIEW FROM

BACK OF SWITCH

SW2

(PTO)

SW7

SHOWN IN

(TILT SW)

SWITCH OPENS

WHEN TILTED

PAST 60 DEGREES

FROM VERTICAL

OFF POSITION

PK/BK

DK.GN

SW3

(BRAKE)

SW6

(SEAT SW)

SHOWN WITH

OPERATOR

IN SEAT

P1–A

DELAY MODULE

100–6186

DISENGAGED

SHOWN WITH

PARK BRAKE

LT.BU

P1–C P2–C

LT.BU

PTO

P1–B

CLUTCH

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

SW4

(NEUTRAL)

LT.GN

(START RELAY)

SHOWN WITH

LEVER IN

SW5

DK.GN

NEUTRAL

POSITION

(NEUTRAL)

GND

Page 49

Cleaning and Storage

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

brake and turn the ignition key to off. Remove spark plug wire. Remove the key.

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

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

Important You can wash the machine with mild

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

3. Service the air cleaner; refer to Servicing the Air

Cleaner, page 28.

4. Grease and oil the machine; refer to Greasing and

Lubrication, page 32.

5. Change the crankcase oil and filter; refer to Servicing

the Engine Oil, page 29.

6. Change the hydraulic filter; refer to Servicing the

Hydraulic System, page 34.

7. Check the tire pressure; refer to Checking the Tire

Pressure, page 33.

8. Charge the battery; refer to Servicing the Battery

page 44.

9. Scrape any heavy buildup of grass and dirt from the

underside of the mower, then wash the mower with a garden hose.

Note: Run the machine with the PTO engaged and the engine at high idle for 2 to 5 minutes after washing.

10.Check the condition of the blades. Refer to Servicing

the Cutting Blades on page 26.

A. Add a petroleum based stabilizer/conditioner to fuel

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

based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline and used at all times.

B. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

refer to Servicing the Fuel Tank, page 32. D. Restart engine and run it until it stops. E. Choke the engine. Start and run engine until it will

not start. F. Dispose of fuel properly. Recycle as per local codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

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

to Servicing the Spark Plug, page 31. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

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

replace any part that is damaged or defective.

14.Paint all scratched or bare metal surfaces. Paint is

available from your Authorized Service Dealer.

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

Remove the key from the ignition switch and keep it in a memorable place out of reach of children or other unauthorized users. Cover the machine to protect it and keep it clean.

11. Prepare the machine for storage when non–use occurs

over 30 days. Prepare machine for storage as follows.

Page 50

Troubleshooting

Problem Possible Causes Corrective Action

Starter does not crank.

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

1. Blade control (PTO) is engaged.

2. Parking brake is not on. 2. Set parking brake.

3. Operator is not seated. 3. Sit on the seat.

4. Battery is dead. 4. Charge the battery.

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

7. Relay or switch is defective. 7. Contact Authorized Service

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

2. Fuel valve turned off. 2. Open fuel valve.

3. Choke is not on. 3. Move choke lever to on.

4. Air cleaner is dirty. 4. Clean or replace air cleaner

5. Spark plug wires are loose or disconnected.

6. Spark plugs are pitted, fouled, or gap is incorrect.

1. Move blade control (PTO) to Disengaged.

5. Check electrical connections for good contact.

Dealer.

element.

5. Install wires on spark plug.

6. Install new, correctly gapped spark plugs.

Engine loses power.

Engine overheats.

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

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

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

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

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

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

5. Spark plugs are pitted, fouled, or gap is incorrect.

6. Dirt in fuel filter. 6. Replace fuel filter.

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

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

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

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

8. Contact Authorized Service Dealer.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plugs.

7. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

Page 51

Problem Corrective ActionPossible Causes

Machine does not drive.

Abnormal vibration.

1. Traction belt is worn, loose or broken.

2. Traction belt is off pulley. 2. Contact Authorized Service

3. Hydro fluid level low. 3. Add hydro fluid to reservoir.

1. Engine mounting bolts are loose.

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

3. Engine pulley is damaged. 3. Contact Authorized Service

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

5. Blade mounting bolt is loose. 5. Tighten blade mounting bolt.

6. Engine mounting bolts are loose.

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

8. Engine pulley is damaged. 8. Contact Authorized Service

1. Contact Authorized Service Dealer.

Dealer.

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

4. Install new cutting blade(s).

6. Tighten engine mounting bolts.

7. Tighten the appropriate pulley.

Dealer.

Uneven cutting height.

Blades do not rotate.

9. Blade spindle bent. 9. Contact Authorized Service Dealer.

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

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

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

4. Gage wheel not set correctly. 4. Adjust gage wheel height.

5. Underside of mower is dirty. 5. Clean the underside of the mower.

6. Tire pressure is incorrect. 6. Adjust tire pressure.

7. Blade spindle bent. 7. Contact Authorized Service Dealer.

1. Mower belt is off the pulley. 1. Install the mower belt and check the adjusting plate, idler arm and spring, and belt guides for correct position

2. Mower belt is worn, loose or

broken.

3. Electric clutch does not

engage.

2. Install a new mower belt.

3. Contact Authorized Service Dealer.

4. Electric clutch is worn. 4. Contact Authorized Service Dealer.

Page 52

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

Outfront and Mid-Mount Z’s ProLine Mid-Size Mowers Groundsmaster Backpack Blowers

• Deck Shells (36″–72″) on the following:

ProLine Mid-Size Mowers Mid-Mount Z’s

• Electric Clutch on 200 Series Mid-Mount Z’s

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

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

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

engine manufacturer.



Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

If you think that your T oro Product contains a defect in materials or workmanship, follow this procedure:

1. Contact any Toro Authorized or Master Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, access our website at www.Toro.com. U.S. Customers may also call 800-348-2424.

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

If for any reason you are dissatisfied with the Service Dealer’s analysis or with the assistance provided, contact us at:

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 888-577-7466 (U.S. customers) 877-484-9255 (Canada customers)

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

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

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

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

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

• Pickup and delivery charges.

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

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

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

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

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

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

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

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

Part No. 374-0037 Rev. C