Toro 74170 Operator's Manual

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Form No. 3323–290

Compact

Z147 with 44 SFS Side Discharge Mower

Model No. 74170–200000001 & Up

Series

Operator’s Manual

Introduction

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

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

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

The warning system in this manual identifies potential hazards and has special safety messages that help you and others avoid personal injury, even death. DANGER, WARNING and CAUTION are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful.

DANGER signals an extreme hazard that will cause serious injury or death if the recommended precautions are not followed.

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

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

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



1. Model

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

Model No:

Serial No.

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

and Serial Number Plate

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

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

IMPORTANT: This engine is not equipped with a spark arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

The Toro Company – 1999

Contents

Page

Safety 3.

Gasoline and Oil 14

Assembly 16

Operation 23

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Safe Operating Practices 3 Toro Mower Safety 5 Slope Chart 9 Safety and Instruction Decals 11

Recommended Gasoline14. . . . . . . . . . . . . .

Using Stabilizer/Conditioner 15 Filling the Fuel Tank 15 Check Engine Oil Level 15

Loose Parts 16 Install Drive Wheels 17 Tire Pressure 17 Install Seat Retaining Rod 17 Install Motion Control Levers 18 Activate the Battery 19 Install Battery 20 Hydraulic System 21

Greasing the Bearings22. . . . . . . . . . . . . . . .

Check the Leveling of Mower Deck 22 Check Side Dischar Check Engine Oil Level 22

Think Safety First 23 Controls 23 Parking Brake 24 Blowout Baf Starting and Stopping

the Engine 25 Operating the Power Take Off (PTO) 26 The Safety Interlock System 27 Testing the Safety Interlock System 27 Driving Forward or Backward 28 Stopping the Machine 28 Instruments 29 Fuel Tanks 29

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fles 24

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ge Chute22. . . . . . . . . . .

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Page

Adjusting Height-of-Cut 30 Adjusting Anti-Scalp Rollers 30 Positioning the Seat 31 Pushing the Machine by Hand 32 Side Discharge 32 T

ransporting Machines33. . . . . . . . . . . . . . . .

Loading Machines33. . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 35

Maintenance 36

Service Interval Chart 36

Cutting Blades37. . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 40 Cleaning the Cooling System 41 Engine Oil 42 Spark Plug 44 Fuel Filter 45 Fuel Tank 45 Greasing and Lubrication 46

Greasing the Bearings47. . . . . . . . . . . . . . . .

Hydraulic System 48 Tire Pressure 50 Castor Pivot Bearing Adjustment 50 Wheel Hub Slotted Nut 51 Mower Leveling 51 Adjusting Push Arms 53 Throttle Lever Adjustment 53 Clean Under Deck 54

Belt Inspection54. . . . . . . . . . . . . . . . . . . . . .

Replacing the Deck Belt55. . . . . . . . . . . . . .

Replacing the Pump Drive Belt 56 Replacing the Grass Deflector 56 Adjusting Motion Controls Adjustment Parking Brake 59 Fuse 59 Battery 60 W

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aste Disposal61. . . . . . . . . . . . . . . . . . . . . .

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Contents

Mercury Tilt Switch 61. Mercury Tilt Switch Disposal 61 Wiring Diagram 62

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Cleaning and Storage 63 Troubleshooting 65 Warranty

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Back Cover

                  

                          

Safety

This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1999 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of certain attachments

that do not meet American National Standards Institute certification will cause noncertification of this machine.

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

Safe

The B71.4—1999.

Operating Practices

following instructions are from ANSI standard

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 ear protection. Long hair, loose clothing or jewelry may get tangled in moving parts.

• Inspect the area where the equipment is to be

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

• Use extra care when handling gasoline and other

fuels. They are flammable and vapors are explosive.

• Use only an approved container

• Never remove gas cap or add fuel with

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

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’ 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.

s responsibility

• 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.

Safety

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from

holes and hidden hazards.

• Be sure all drives are in neutral and parking

brake is engaged before starting engine. Only start engine from the operator’ seat belts if provided.

• Slow down and use extra care on hillsides. Be

sure to travel in the recommended direction on hillsides. Turf conditions can affect the machine’ near drop–offs.

• Slow down and use caution when making turns

and when changing directions on slopes.

• Never raise deck with the blades running.

• Never operate with the PTO shield, or other

guards not securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property.

s stability

. Use caution while operating

s position. Use

• Never carry passengers and keep pets and

bystanders away

• Slow down and use caution when making turns

and crossing roads and sidewalks. Stop blades if

not mowing.

• Be aware of the mower discharge direction and

do not point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs

• Use care when loading or unloading the machine

into a trailer or truck

• Use care when approaching blind corners,

shrubs, trees, or other objects that may obscure

vision.

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.

• 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 (if provided), shut off engine before leaving the operator’s position for any reason including emptying the catchers or unclogging the chute.

• Stop equipment and inspect blades after striking

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

• Keep hands and feet away from the cutting units.

• Look behind and down before backing up to be

sure of a clear path.

• 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.

Safety

• 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.

Toro

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the ANSI standards.

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

Mower Safety

Note: 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.

General Operation

• Allow only responsible adults who are familiar

with the instructions to operate the machine.

• Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely

necessary. Always look down and behind before and while backing.

• Be aware of the mower discharge direction and

do not point it at anyone. Do not operate the mower without either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any

terrain may cause loss of control.

POTENTIAL HAZARD

• Engine exhaust contains carbon monoxide,

which is an odorless, deadly poison.

WHAT CAN HAPPEN

• Carbon monoxide can kill you and is also

known to the State of California to cause birth defects.

HOW TO AV

OID THE HAZARD

• Do not run engine indoors or in an enclosed

area.

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.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away

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

• Stop the engine before removing the grass

catcher or unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts

which may be hot from operation. Allow to cool before attempting to maintain, adjust or service.

Safety

• Before operating a machine with ROPS (roll

over protection) be certain the seat belts are attached to prevent the seat from pivoting forward.

Slope Operation

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

• Mow up and down slopes greater than 5°, not

across.

• Mow downhill only on slopes above 10°, never

mow uphill. If a steep slope must be ascended, back up the hill, and drive forward down the hill, keeping the machine in gear.

• Remove obstacles such as rocks, tree limbs, etc.

from the mowing area. Watch for holes, ruts or bumps, as uneven terrain could overturn the machine. T

• Use slow speed so that you will not have to stop

while on the slope.

• Follow the manufacturer’s recommendations for

wheel weights or counterweights to improve stability.

all grass can hide obstacles.

• When operating a machine with ROPS (roll over

protection) always use seat belt.

• Be certain that the seat belt can be released

quickly if the machine is driven or rolls into

ponds or water.

• Check carefully for overhead clearances (i.e.

branches, doorways, electrical wires) before

driving under any objects and do not contact

them.

DO NOT

• Do not operate machine on hillsides or slopes

exceeding 15

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

slowly and gradually downhill, if possible.

• Do not mow near drop-offs, ditches, or

embankments. The machine could suddenly turn

over if a wheel goes over the edge of a cliff or

ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction

could cause sliding.

• Do not try to stabilize the machine by putting

your foot on the ground.

• Do not use a grass catcher on steep slopes.

Heavy grass bags could cause loss of control or

overturn the machine.

°.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual.

Do not make sudden changes in speed or direction.

• Avoid starting or stopping on a slope. If tires

lose traction, disengage the blades and proceed slowly straight down the slope.

• When operating machine on slopes, banks or

near drop offs, always have ROPS (roll over protection) installed.

Service

• Never store the machine or fuel container inside

where there is an open flame, such as near a

water heater or furnace.

• Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good

condition.

• Never tamper with safety devices. Check safety

systems for proper operation before each use.

• Use only genuine replacement parts to ensure

that original standards are maintained.

• Check brake operation frequently. Adjust and

service as required.

• Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes and clothing. Protect your face, eyes and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes,

sparks and flames away from battery.

• Hydraulic fluid escaping under pressure can

penetrate the skin and cause injury. Use cardboard or paper to find hydraulic leaks.

• Never modify ROPS (roll over protection)

frames or structures because they are specifically designed, sized, located and tested for injury reduction. If a rollover occurs, a modified ROPS will not provide adequate protection.

Safety

Safety8Safety

Slope

Read all safety instructions on pages 5–7.

Chart

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.

ON RIGHT SIDE OF HEIGHT OF

CUT PLA

(Part No E653140)

OP OF CONSOLE UNDER SEA

(Part No. E513747)

ON LEFT SIDE OF

HEIGHT–OF–CUT PLA

(Part No E653147)

ON T

OP OF CONSOLE LEFT

AND RIGHT SIDES

(Part No. E633354)

BELOW CENTER OF CONSOLE

(Part No. E633346)

ON FRAME UNDER SEA

(Part No. E603845)

ON T

OP OF HYDRAULIC RESERVOIR

(Part No. E523552)

ON TIL

(Part No. E643401)

OP OF CONSOLE

UNDER SEA

(Part No. E643372)

T SWITCH

Safety

UNDER FOOTREST

(Part No. 99–3924)

ON FRAME NEAR MUFFLER

(Part No. 65–2690)

LOWER LEFT OF CONSOLE

(Part No. 98–4387)

YEA RLY

ON T

OP LEFT SIDE OF FRAME

(Part No. E633818)

ON CONTROL P

(Part No. 99–3942)

ANEL

Safety

ON RIGHT SIDE OF MOWER

(Part No. 66-1340)

ON LEFT SIDE OF MOWER

(Part No. 43-8480)

UNDER DEFLECTOR

(Part No. 66-6380)

ON DEFLECTOR

(Part No. 54-9220)

UNDER BELT COVER (3)

(Part No. 98Ć5954)

(2) ON BELT COVERS

 (1) UNDER FOOT REST

(Part No. 67-5360)

ON TOP CENTER OF MOWER

(Part No. 99-3943)

99–3943

ON TOP OF MOWER IN CENTER

(Part No. 98-3798)

ON LEFT FRONT OF MOWER

(Part No. 93-7818)

Gasoline and Oil

Recommended

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

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

POTENTIAL HAZARD

Gasoline

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

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

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

• Do not fill the fuel tank completely full.

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

• Never smoke when handling gasoline, and

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

• Store gasoline in an approved container

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

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Always place gasoline containers on the

ground away from your vehicle before filling.

• Do not fill gasoline containers inside a

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

• When practical, r

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

emove gas–power

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used,

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

Gasoline and Oil

POTENTIAL HAZARD

• Gasoline is harmful or fatal if swallowed.

Long–term eposure to vapors has caused cancer to laboratory animals.

WHAT CAN HAPPEN

• Failure to use caution may result in serious

injury or illness

HOW TO AV

OID THE HAZARD

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank

or conditioner opening.

• Keep gas away from eyes and skin.

Using

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

Stabilizer/Conditioner

Filling

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

2. Clean around each fuel tank cap and remove the

3. Install fuel tank caps securely. Wipe up any

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 42.

the Fuel T

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

gasoline that may have spilled.

ank

Engine Oil Level

• 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.

Assembly

Loose

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

DESCRIPTION QTY. USE

Rear Wheels Retaining rod

Bolt 5/16–18 x 1” (26 mm) Locknut 5/16”

Control lever–right Control lever–left Bolt 3/8–1 x 1” (26 mm) Spring washer 3/8”

Key Operator’ Engine Operator’s Manual Parts Catalog Registration card

Parts

s Manual

2 1

1 1

1 1 4 4

2 1 1 1 1

Install wheels to traction unit

Install seat rod

Install motion control levers

Read before operating machine

Fill out and return to T

oro

Assembly

Install

Drive Wheels

1. Uncrate mower.

1. Remove wheel bolts or nuts from rear wheel

hubs.

2. Align holes. Mount drive wheels with the valve

stem to the outside of the traction unit.

3. Secure using wheel bolts or nuts provided.

Torque to 95ft–lbs (128 NSM).

Tire

Pressure

Check the air pressure in the front and rear tires (Fig. 1).

Pressure: 13 psi (90 kPa)

Install

Seat Retaining Rod

4. Tilt seat up. Remove 5/16” (8mm) locknut from

bolt attaching seat retaining rod to seat frame (Fig. 2).

5. Remove retaining rod from seat and insert the

”L” shaped end of the rod into the hole directly above the left–side hydraulic pump mounting hardware (Fig. 2).

6. Place the seat retaining rod to the outside of the

mounting tab of the seat frame and secure with 5/16–18 x 1” (26 mm) bolt and 5/16” (8mm) locknut (Fig. 2).

7. Tighten until snug, then loosen so the rod pivots

freely.

Figure 1

1. Valve

stem

m–1872

m–3750

Figure 2

1. L

end of retaining rod

Locknut 5/16”

Bolt 5/16–18 x 1” (26 mm)

Assembly

Install

Motion Control Levers

8. Remove the (4) 3/8–16 x 1” (26 mm) bolts and

(4) 3/8” spring washers which attach the motion control levers to the control arm shafts for shipping (Fig. 3).

9. Place the levers (with the mounting plate

towards the rear) on the outside of the control arm shaft and secure with (4) 3/8–16 x 1” (26 mm) bolts and (4) 3/8” spring washers (Fig. 3).

10. Position the lever so the bolts are in the center of

the slots on the lever mounting plate and tighten until snug.

11. Align the front\rear position of the levers, with

each other, in the neutral position. Loosen hardware and adjustment by sliding/tilting the lever(s) forward or backward until properly aligned(Fig. 3).

12. If the ends of the levers hit against each other,

while in the drive position (Fig 4) (levers rotated in as far as possible) make adjustments by moving the levers outwards to the neutral lock position and carefully bend them outward. Move them back to the drive position and check for clearance. Repeat if necessary.

Figure 4

1. Mounting

Bolt 3/8–18 x 1” (26 mm)

plate

Figure 3

Spring washer 3/8”

m–3751

Assembly

Activate

the Battery

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

1. Remove the battery from the machine. IMPORTANT: Be careful not to damage the

long vent tube when removing the battery box.

POTENTIAL HAZARD

• Battery electrolyte contains sulfuric acid

which is a deadly poison and it causes severe burns.

WHAT CAN HAPPEN

• If you carelessly drink electrolyte you could

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

HOW TO AV

OID THE HAZARD

• Do not drink electrolyte and avoid contact

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

2. Remove filler caps from the battery. Slowly pour

electrolyte into each cell until the electrolyte level is up to the lower part of the tube (Fig. 5).

m–1262

Figure 5

1. Filler

2. Electrolyte

caps

Lower part of the tube

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

battery charger to the battery posts (Fig. 6). Charge the battery at a rate of 4 amperes or less for 4 hours (12 volts).

1. Positive

Negative post

post

Figure 6

Charger red (+) wire

Charger black (–) wire

m–1254

Assembly

Install Battery

POTENTIAL

• Charging battery pr

HAZARD

oduces gasses.

WHAT CAN HAPPEN

•

Battery gasses can explode causing serious injury.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

•

Make sur

e the ignition switch is in the

“OFF” position.

• Ventilate when charging or using battery in

an enclosed space.

•

Make sur open when battery is filled with acid.

4. When the battery is fully charged, disconnect the

charger from the electrical outlet then from the negative and positive battery posts (Fig. 6).

5. Slowly pour electrolyte into each cell until the

level is once again up to the lower part of the tube and install covers (Fig. 5).

e venting path of battery is always

1. Position battery in tray with terminal posts

toward the engine (Fig. 7).

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) 1/4 x 3/4” (19 mm) bolts

1/4” washers and 1/4” locknuts (Fig. 7).

5. Slide the red terminal boot onto the positive

(red) battery post.

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

and (2) 1/4” washers and (2) 1/4” wing nuts (Fig. 7).

7. Position drain tube away from belts and other

parts to prevent corrosion.

9 5

6. Wash off any spilled acid with water. Dry off the

battery.

1. Battery

2. Terminal

6. Bolt

boot Positive battery cable Negative battery cable Ground wire

1/4–20 x

Figure 7

3/4” (19 mm)

7. Washer

Locknut 1/4”

Battery clamp

10. J-bolts

11.

Wing nut 1/4”

12.

Drain T

6 7

m–3752

1/4”

ube

Assembly

Hydraulic

System

Checking the Hydraulic Fluid

Check the hydraulic fluid level before engine is first started.

Fluid Type: Mobil 1 15W–50 synthetic motor oil.

IMPORTANT: Use only oil specified. Other fluids could cause system damage.

Hydraulic System Oil Capacity: 2.1 qt. (2.0 l)

1. Position machine on a level surface and set the

parking brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 8).

3. Remove cap from filler neck. Look inside to

check if there is fluid in the reservoir. (Fig. 8).

4. If there is no fluid, add fluid to reservoir

aproximately a 1/4(6mm) below the top of baffle.

5. Run the machine 15 minutes to allow any air to

purge out of the system and warm fluid.

Figure 8

1. Cap

2. Baffle

POTENTIAL

HAZARD

3. Fluid

level-Full

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.



6. Recheck level while fluid is warm. Add fluid to

raise level to top of the baffle, if required. Note: Fluid level should be to the top of the

baffle when fluid is warm (Fig. 8).

7. Install cap on filler neck.

HOW TO AV

•

Make sur lines ar

OID THE HAZARD

e all hydraulic fluid hoses and

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

• 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.

Assembly

Greasing

Make sure cutting unit spindles are full of grease before engine is first started.

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

1. Grease the fittings on the three spindle bearings.

Grease until it comes out lower seals (Fig. 9).

the Bearings

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 42.

Engine Oil Level

M-4269

Figure 9

1. Spindles

Check

the Leveling of Mower

Deck

Check the level of the deck before machine is first put into use.

Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 51.

Check

Remove plastic tie holding side discharge chute up and lower into place.

Side Discharge Chute

Operation

Think

Safety First

Please carefully read all the safety instructions on pages 3–13. Knowing this information could help you, your family, pets or bystanders avoid injury.

POTENTIAL HAZARD

• Loud sound can cause ear damage and loss

of hearing.

WHAT CAN HAPPEN

• Ear damge or hearing loss may occur.

HOW TO AV

OID THE HAZARD

• Wear ear protection when operating this

machine.

Controls

Become familiar with all the controls (Fig. 1) before you start the engine and operate the machine.

1. Ignition

4. Throttle

5. Choke

switch Motion control lever Parking brake lever

f (PT

f valve

m–4200

Figure 1

Power take of

Height-of-Cut lever

Fuel cap

9. Hourmeter

10.

Fuel shut-of

Operation

Parking Brake

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

IMPORTANT: Do not park on slopes unless wheels ar

Setting the Parking Brake

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

the neutral lock position.

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

set the parking brake (Fig. 2). The parking brake lever should stay firmly in the “ENGAGED” position.

e chocked or blocked.

Releasing the Parking Brake

1. Push forward and down on the parking brake

lever to release the parking brake (Fig. 2). The parking brake is “DISENGAGED”.

Figure 2

1. Parking

brake-ON

Parking brake-OFF

m–4121

Blowout

Baffles

Blowout baffles are used when in side discharge mode only.

IMPORTANT: Do not use blowout baffles while in recycling mode.

1. To install or remove blowout baffles, install or

remove bolts as shown in figure 3.



Figure 3

1. Bolts

2. Front

of Deck

3. Baffles

Operation

Starting

and Stopping

the Engine

Starting

1. Sit down on the seat and move the motion

controls to neutral locked position.

2. Set the parking brake; refer to Setting the

Parking Brake, page 24.

3. Move the PTO (power take off) to “OFF”

(Fig. 4).

4. Move the choke control to “ON” position before

starting a cold engine (Fig. 5). Note: A warm or hot engine may require

choking. After engine starts, move choke control to “OFF” position.

5. Move the throttle control to the “FAST” position

before starting a cold engine (Fig. 6).

Figure 4

1. PTO-On

2. PTO-Off

m–4201

m–2719

Figure 5

1. Choke–On

2. Choke–Off

6. Turn ignition key to “START” to energize starter.

When engine starts, release key (Fig. 7).

IMPORTANT: Do not engage starter for more than 10 seconds at a time. If engine fails to start allow 30 second cool-down period between attempts. Failure to follow these instructions can burn out starter motor.

7. After the engine starts, move the choke to “OFF”

(Fig. 5). If the engine stalls or hesitates, move the choke back to “ON” for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.

1. Fast

2. Slow

Figure 6

m–2720



Figure 7

1. Off

2. Run

3. Start

Operation

Stopping

1. Move the throttle lever to “SLOW” (Fig. 6).

2. Move the PTO (power take off) to “OFF”

(Fig. 4).

3. Turn the ignition key to “OFF” (Fig. 7). Note: If the engine has been working hard or

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

4. Pull wire off spark plug(s) to prevent possibility of someone accidentally starting the machine before transporting or storing machine.

5. Close fuel shut off valve, on front panel before transporting or storing machine.

Operating

the Power T

ake Off

(PTO)

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

Engaging the PTO

1. Release pressure on the traction control levers

and place in neutral.

2. Release the parking brake, page 24.

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

engage (Fig. 8).

IMPORTANT: Make sure fuel shut off valve is closed before transporting or storing machine, as fuel leakage may occur.

m–4201

Figure 8

1. PTO

– Of

f2.PT

O – On

Disengaging the PTO

1. To disengage push the PTO switch to the “OFF”

position (Fig. 8).

The

Safety Interlock System

Testing

Operation

the Safety Interlock

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 parking brake is on “ENGAGED”

• The power take off (PTO) is disengaged “OFF”

• The motion control levers are in 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” engaged.

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” parking brake

and move PTO “ON”. Try starting the engine; the engine should not crank.

2. Sitting on the seat, “ENGAGE” parking brake

and move PTO “OFF”. Move either motion control lever (forward or reverse). Try starting the engine; the engine should not crank. Repeat with other motion control lever.

3. Sitting on the seat, “ENGAGE” parking brake,

move PTO “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” parking brake,

PTO “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.

5. Sitting on the seat, “DISENGAGE” parking

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

Operation

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

POTENTIAL HAZARD

• Machine can spin very rapidly by

positioning one lever too far ahead of the other.

WHAT CAN HAPPEN

• Operator may lose control of the machine

and cause injury or damage to machine.

HOW TO AV

OID THE HAZARD

• Use caution when making turns.

• Slow the machine down before making

sharp turns.

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.

1. Motion

control

lever-neutral lock position Center un-lock position

Figure 9

m–2715

3. Forward

4. Backward

Backward

1. Move levers to the center, un-locked position.

Forward

1. Release the parking brake; refer to Releasing the Parking Brake, page 24.

2. Move levers to the center, un-locked position.

3. To go forward, slowly push the motion control

levers forward (Fig. 9). Note: Engine will kill if traction control

levers are moved with parking brake engaged.

To go straight, apply equal pressure to both motion control levers (Fig. 9).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 9).

2. To go backward, slowly pull the motion control

levers rearward (Fig. 9).

To go straight, apply equal pressure to both motion control levers (Fig. 9).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 9).

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 24. Remember to remove the key from the ignition switch.

Fuel Tanks

Operation

POTENTIAL HAZARD

• Someone could move or attempt to operate

the tractor while it is unattended.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the tractor.

HOW TO AV

•

Always r

OID THE HAZARD

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

Instruments

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.

The unit has two fuel tanks, one located 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.

11). To use the right side fuel tank rotate the fuel shut off

valve 1/4 turn to the right from the off location. This uses fuel from the right side tank only. When the right fuel tank is empty, move the fuel shut off valve 1/4 turn to the left from the off position.

Close fuel shut off valve, on front panel before transporting or storing machine.

1. Shut

Figure 1

f valve

1. Hour

m–4202

Figure 10

meter

Operation

Adjusting

Height-of-Cut

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

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

position (also the 4-1/2” (114 mm) cutting height position) (Fig. 12).

2. To adjust, remove hairpin cotter and clevis pin

from height-of-cut bracket (Fig. 12).

3. Select hole in height-of-cut bracket

corresponding to the height-of-cut desired. Lift handle to transport position, insert clevis pin (Fig. 12).

4. Secure clevis pin with hairpin cotter (Fig. 12).

Adjusting

Anti-Scalp Rollers

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

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

ignition key to “OFF” to stop the engine. Move controllers to neutral locked position and apply parking brake. Remove the key.

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

washer while holding stud with wrench (Fig. 13).

Note: Do not remove the wheel nut and

washer (Fig. 13).

3. Select hole so gage wheel is positioned to the

nearest corresponding height-of-cut desired (Fig.

(Fig. 13).

4. Reinstall the stud nut and washer (Fig. 13).

1. Height

Clevis Pin

of cut lever

Figure 12

Hairpin Cotter



5. Repeat adjustment on other gage wheels.

Figure 13

1. Gage

2. Stud

3. Washer

Wheel

4. Nut

Wheel nut and washer Do Not Remove.

m–4167

Operation

Center Rollers

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

ignition key to “OFF”. Move controllers to neutral locked position and apply parking brake.

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

nut (Fig. 14).

3. Select hole so gage wheel is positioned to the

nearest corresponding height-of-cut desired (Fig. 14).

Note: Do not adjust rollers to support the

deck.

4. Reinstall the bolt, center rollers and nut

(Fig. 14).

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. 15).

2. Slide the seat to the desired position and release

lever to lock in position.

m–3655

1200

1. Center

2. Nut

Figure 14

Rollers and Spacer

3. Bolt

m–4124

Figure 15

1. Adjustment

knob

Operation

Pushing

IMPORTANT: Always push the machine by hand. Never tow the machine because hydraulic damage may occur.

the Machine by Hand

To Push the Machine

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

ignition key to “OFF” to stop the engine.

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. 16).

IMPORTANT: Never rotate by-pass valve more than 2 turns so the valve does not come out of the body causing fluid to run out.

To Operate the Machine

1. Turn the by-pass valves in to operate (Fig. 16). Note: The machine will not drive unless

by-pass valves are turned in.

Side

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

Discharge

POTENTIAL HAZARD

• Without the grass deflector or complete

grass catcher assembly mounted in place, you and others are exposed to blade contact and thrown debris.

WHAT CAN HAPPEN

• Contact with rotating mower blade(s) and

thrown debris will cause injury or death.

HOW TO AV

•

NEVER r the mower because the grass deflector routes material down toward the turf. If the grass deflector is ever damaged, replace it immediately.

OID THE HAZARD

emove the grass deflector from

• 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(s) off the spark plug(s).

1. By-pass

Figure 16

valve

Operation

Transporting

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 on pages 3–13. Knowing this information could help you, your family, pets or bystanders avoid injury.

To transport the machine:

• Lock brake and block wheels.

• Securely fasten the machine to the trailer or

truck with straps, chains, cable, or ropes.

• Secure a trailer with a safety chains to towing

vehicle.

POTENTIAL HAZARD

Machines

• This unit does not have proper turn signals,

lights, reflective markings, or a slow moving vehicle emblem. These items are required to drive on a public street or roadway.

WHAT CAN HAPPEN

• Driving on a street or roadway without

such equipment is dangerous and can lead to accidents causing personal injury.

• Driving on a street or roadway without

such equipment may also be a violation of State laws and the operator may be subject to traffic tickets and/or fines.

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. 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.

Ramp should be long enough so that the angles between the ramp and the ground and the ramp and the trailer or truck do not exceed 15 degrees. 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.

Machines

HOW TO AV

OID THE HAZARD

• Do not drive machine on a public street or

roadway.

Operation

POTENTIAL HAZARD

• Loading a unit on a trailer or truck

increases the possibility of backward tip–over.

WHAT CAN HAPPEN

• Backward tip–over of the unit could cause

serious injury or death.

HOW TO AV

•

Use extr on a ramp.

OID THE HAZARD

eme caution when operating a unit

• 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.

Operation

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 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 six inches 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.

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.

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

Mowing Direction

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

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.

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 immediately with a genuine T blade.

. If a blade is damaged or worn, replace it

ORO replacement

Maintenance

Service

Hydraulic fluid–check level Oil—check level Oil—change* Initial X X Oil Filter–change (200 hours or

every other oil change) Hydraulic filter–change Safety System—check Chassis—grease* X X Linkage bushings—oil* Foam Air Cleaner—service* Paper Air Cleaner—service* Paper Air Cleaner—replace* Spark Plug(s)—check Belts—check for wear/cracks Gasoline—drain X Cooling systems–clean Hydraulic lines–check Battery–check electrolyte Battery–charge, Disconnect cables Fuel Filter—replace T

ires—check pressure Chipped Surfaces—paint Cutting Blades – check Blade Spindle Bearings – grease Idler Pulley Pivot Mower Housing – clean

Castor Pivot – adjustment *

More often in dusty

Interval Chart

Operation

, dirty conditions

Each

Use8Hours25Hours50Hours

Initial Initial X X

X X

Initial X X

X X

X X X X

X X

X X X

X X

X X X

X X

100

Hours

X X

200

Hours

X X

300

Hours

X X

Storage

Service

500hrs or

at Storage

POTENTIAL HAZARD

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

WHAT CAN HAPPEN

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

Maintenance

HOW TO AV

OID THE HAZARD

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

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

Cutting

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 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.

Blades

. If a blade is damaged

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” to stop the engine. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

POTENTIAL HAZARD

• A blade that is worn or damaged could

break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

OID THE HAZARD

• Periodically inspect the blade for wear and

damage. Immediately install a new blade if it is worn or damaged.

Maintenance

Inspecting the Blades

1. Inspect the cutting edges (Fig 17). If the edges

are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 39.

2. Inspect the blades, especially the curved area

(Fig. 17). If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 17), immediately install a new blade.

Checking for Bent Blades

1. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Rotate the blades until the ends face forward and

backward (Fig. 18). Measure from a level surface to the cutting edge of the blades (Fig.

19). Note this dimension.



m–1078

Figure 18

1. Cutting

Curved Area

Edge

Figure 17

3. W

ear/slot Forming

m–151

 

   

 

Figure

m–2539

3. Rotate the opposite ends of the blades forward.

Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8” (3 mm). If this dimension exceeds 1/8” (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 39.

POTENTIAL HAZARD

• A blade that is bent or damaged could

break apart and pieces could be thrown at bystanders or at you as you use the mower.

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

•

Always r

OID THE HAZARD

eplace bent or damaged blade with

a new blade.

• Never file or create sharp notches in the

edges or surfaces of blade.

Maintenance

Sharpening the Blades

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

ends of the blade (Fig. 21). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

Figure 21

1. Sharpen

at original angle

m–1854

Removing the Blades

Blades must be replaced if a solid object is hit, if the blade is out of balance or is bent. To ensure optimum performance and continued safety conformance of the machine, use genuine T 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, flat washer, split lockwasher and blade from the spindle shaft (Fig. 20).

1. Sail

Area of Blade

2. Blade

Flat W

asher

ORO replacement blades.

Figure 20

Blade Bolt

Split Lockwasher



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

blade balancer (Fig. 22). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 20). Repeat this procedure until the blade is balanced.

Figure 22

1. Blade 2. Balancer

m–1855

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 20). 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. 20). Torque the blade bolt to 85–110 ft-lb (115–150 NSm).

Maintenance

Air

Cleaner

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

Paper Element: Clean after every 100 operating hours. Replace after every 300 operating hours or yearly. Which ever comes first.

Note: Service the air cleaner more frequently

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

Removing the Foam and Paper Elements

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

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

2. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Unlatch two side latches and remove the air cleaner cover (Fig. 23).

3. Carefully remove the foam element from the

paper element (Fig. 23).

4. Unscrew the wing nut and remove the paper

element (Fig. 23).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and

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

B. Dry the element by squeezing it in a clean

cloth (do not wring).

C. Soak element in new engine oil. (Fig. 24).

Squeeze the element to remove excess oil.

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

1. Cover

2. Foam

Paper element

element

3 5

Figure 23

Wing nut

Air cleaner base

6. Latches

M-4289

1. Foam

element

Figure 24

2. Oil

Maintenance

2. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 25).

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

and damage to the rubber seal.

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

Cleaning

the Cooling System

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

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

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

2. Remove air–intake screen, cylinder covers and fan housing.

3. Clean debris and grass from parts.

4. Reinstall air–intake screen, cylinder covers and

fan housing.

M-4293

Figure 25

1. Paper

element

Rubber seal

Installing the Foam and Paper Elements

IMPORTANT: To prevent engine damage, always operate the engine with the complete foam and paper air cleaner assembly installed.

1. Carefully slide the foam element into the paper

air cleaner element (Fig. 23).

2. Place the air cleaner assembly onto the air

cleaner base and install wing nut (Fig. 23).

3. Install the air cleaner cover and latch (Fig. 23).

1. Air–intake

Fan Housing

Screen

Figure 26

m–4295

Cylinder Cover Cylinder Cover

Maintenance

Engine

Oil

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when

operating conditions are extremely

dusty or sandy. Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 1.9 qt. (1.8 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

Checking Oil Level

1. Park the machine on a level surface, disengage

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

2. Clean around the oil dipstick (Fig. 27) so dirt

cannot fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the end clean

(Fig. 27).

4. Slide the oil dipstick fully into the filler tube, do

not thread onto tube (Fig. 27). Pull the dipstick out and look at the end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark.

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

m–429

1. Oil

Filler tube

dipstick

Figure 27

M-4291

Dipstick end

Maintenance

Changing/Draining Oil

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

warms the oil so it drains better.

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

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

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

screw driver, 3/8” wrench or 10mm wrench to open valve (Fig. 28).

4. Rotate valve end clockwise to close valve.

Rotate valve end counterclockwise to open valve (Fig. 28).

5. When oil has drained completely, close the drain

valve (Fig. 28). Note: Dispose of the used oil at a certified

recycling center.

Change Oil Filter

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

Note: Change oil filter more frequently when

operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to

Changing/Draining Oil, page 43.

2. Remove the old filter (Fig. 29).

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

on the replacement filter (Fig. 29).

m–4674

Figure 28

1. Oil

drain valve

6. Slowly pour approximately 80% of the specified

amount of oil specified, page 42, into the filler tube (Fig. 27). Now check the oil level; refer to Checking Oil Level, page 42. Slowly add additional oil to bring to “FULL” mark on dipstick.



Figure 29

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. 29).

5. Fill the crankcase with the proper type of new

oil; refer to Changing/Draining Oil, page 42.

Maintenance

Spark

Plug

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

Type: Champion RCJ8Y (or equivalent) Air Gap:

0.040 in. (1.0 mm)

Removing the Spark Plug(s)

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

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

2. Pull the wire(s) off the spark plug(s) (Fig. 30).

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

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 31).

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

IMPORTANT: Never clean the spark plug(s). Always r a black coating, worn electrodes, an oily film, or cracks.

2. Check the gap between the center and side

electrodes (Fig. 31). Bend the side electrode (Fig. 31) if the gap is not correct.

eplace the spark plug(s) when it has

0.040

in.

(1.0 mm)

3. Remove the spark plug(s).

Figure 30

1. Spark

plug wire installed

Spark plug



m–3215

1. Center

Side electrode

Figure

electrode insulator

Air gap (not to scale)

Installing the Spark Plug(s)

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

set correctly.

2. Tighten the spark plug(s) to 11 ft-lb (15 N.m).

3. Push the wire(s) onto the spark plug(s) (Fig. 30).

Maintenance

Fuel

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

Filter

Replacing the Fuel Filter

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

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

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

2. Close fuel shut–off valve on console.

3. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 32).

4. Remove the filter from the fuel lines.

5. Install a new filter and move the hose clamps

close to the filter (Fig. 33).

Fuel Tank

Draining The Fuel Tank

POTENTIAL

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

• Drain gasoline from the fuel tank when the

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

• Never drain gasoline near an open flame or

where gasoline fumes may be ignited by a spark.

• Never smoke a cigarette, cigar or pipe.

HAZARD

OID THE HAZARD

6. Open fuel shut-off valve on console.

Figure 32

1. Filter 2. Hose

clamp

1. Park the machine on a level surface, to assure

fuel tanks drain completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to “OFF” to stop the engine. Remove the key.

2. Close fuel shut–off valve (Fig. 33).

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

it up the fuel line away from the fuel filter (Fig. 33).



Maintenance

4. Pull the fuel line off fuel filter (Fig. 33).

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

Allow gasoline to drain into a gas can or drain pan. (Fig. 33).

Note: Now is the best time to install a new

fuel filter because the fuel tank is

empty.

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

hose clamp close to the fuel filter to secure the fuel line (Fig. 33).

Greasing

and Lubrication

Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 34). 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 power take off (PTO) and turn the

ignition key to “OFF” to stop the engine. Remove the key.

2. Clean the grease fittings with a rag. Make sure to

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

3. Connect a grease gun to the fitting. Pump grease

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

1. Fuel

Fuel filter

shut-of

f valve

Figure 33

Hose clamp Fuel line



4. Wipe up any excess grease.

Where to Add Grease

Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 34).

Figure 34

Grease Front Castor Pivots

Lubricate the front castor pivots once a year.

1. Remove hex plug and cap. Thread a grease zerk

into hole.

2. Pump grease into zerk until it oozes out around

top beraring.

3. Remove grease zerk in hole. Reinstall hex plug

and cap.

Maintenance

Greasing

The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 36. Grease with No. 2 general purpose lithium base or molybdenum base grease.

1. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Grease the fittings on the three spindle bearings

(Fig. 35).

3. Grease the idler pulley pivot (Fig. 35).

4. Grease the fittings on the push arms(Fig. 35).

the Bearings

M-4269

Figure 35

Maintenance

Hydraulic

System

Checking the Hydraulic Fluid

Check the hydraulic fluid level:

• Before engine is first started.

• After first 8 operating hours.

• After 25 operating hours.

Fluid Type: Mobil 1 15W–50 synthetic motor oil.

IMPORTANT: Use only oil specified. Other fluids could cause system damage.

System Capacity: 2.1 qt. (2.0 l)

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 36).

3. Remove cap from filler neck. Look inside to

check if there is fluid in the reservoir. (Fig. 36).

4. If there is no fluid, add fluid to reservoir

approximately a 1/4(6mm) below the top of baffle.

5. Run the machine 15 minutes to allow any air to

purge out of the system and warm fluid.

6. Recheck level while fluid is warm. Add fluid to

raise level to top of the baffle, if required. Note: Fluid level should be to the top of the

baffle when fluid is warm (Fig. 36).

7. Install cap on filler neck.

Figure 36

1. Cap

2. Baffle

POTENTIAL

HAZARD

3. Fluid

level-Full

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

HOW TO AV

•

Make sur lines ar

OID THE HAZARD

e all hydraulic fluid hoses and

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

• 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.



Replacing the Hydraulic Filter

Maintenance

Change the hydraulic filter:

• After the first 8 operating hours.

• After every 200 operating hours.

1. Position machine on a level surface, stop the

engine, and remove key from ignition switch.

IMPORTANT: Do not substitute automotive oil filter or severe hydraulic system damage may result.

2. Remove hydro cap and temporarily cover

opening with a plastic bag and rubber band to prevent all hydro fluid from draining out.

A. Place drain pan under filter, remove the old

filter and wipe the filter adapter gasket surface clean (Fig. 37).

1. Hydraulic

2. Gasket

filter

Figure 38

3. Adapter

m–1256

7. Clean up any spilled fluid.

8. Start engine and let run for about two minutes to

purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 49.

9. Check fluid level in hydraulic tank and add to

raise level to the top of baffle. DO NOT OVER FILL.

m–4117

Figure 37

1. Hydraulic

filter

3. Apply a thin coat hydro fluid to the rubber

gasket on the replacement filter (Fig. 38).

4. Install replacement hydraulic filter onto the filter

adapter. Do not tighten.

5. Remove plastic bag from tank opening and allow

filter to fill with hydro fluid.

6. When fluid overflows filter turn the oil filter

clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 38).

Bleeding Hydraulic System

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

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

ground and support with jack stands.

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

traction on one side and spin the wheel by hand.

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

it engaged until wheel drives smoothly. (minimum 2 minute)

4. Check hydraulic fluid level as it drops and add

as required to maintain proper level.

5. Repeat procedure on opposite wheel.

Maintenance

Check 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.

POTENTIAL HAZARD

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.

HOW TO AV

•

Make sur lines ar

OID THE HAZARD

e all hydraulic fluid hoses and

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

• 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.

m–1872

Figure 39

Castor

1. Valve

Pivot Bearing

stem

Adjustment

Check after every 500 operating hours or at storage which ever comes first.

1. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove dust cap from castor and tighten lock

nut (Fig. 40).

3. Tighten until spring washers are flat and then

back off a 1/4 turn to properly set the pre–load on the bearings (Fig. 40).

IMPORTANT: Make sur installed correctly as shown in figure 40.

e spring washers ar

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 50 operating hours or monthly, whichever occurs first (Fig. 39). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 13 psi (90 kPa) drive wheels and castor wheels.

1. Spring Washers

Lock Nut

Figure 40



Dust Cap

Maintenance

Wheel

Hub Slotted Nut

Check after every 500 operating hours. The slotted nut needs to be torqued to 125 ft–lbs

(169.5 NSm).

1. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove cotter pin.

3. Torque slotted nut to 125 ft–lbs (169.5 NSm)

(Fig. 41).

4. Check the distance from bottom of slot in nut to

inside edge of hole. Two threads or less should be showing (Fig. 41).

5. If more than two threads are showing remove nut

and install washer between hub and nut (Fig. 41).

6. Torque the slotted nut to 125 ft–lbs (169.5 NSm)

(Fig. 41).

Mower

Leveling

1. Position mower on a flat surface. Stop the

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

2. Check tire pressure of all four (4) tires. If

needed, adjust to 13 psi (90 kPa)

3. Set anti–scalp rollers to top holes or remove

them completely for this adjustment.

4. Raise the deck to the transport position (Fig. 42).

Take force off of the two large deck lift springs by loosening jam nut and front spring nut, in front of each spring, as far as possible (Fig. 43).

5. Place two 1-1/4” (35 mm) thick blocks under

rear left and right lower edge of mower. Place one 1-3/8” (44 mm) block under front center lower edge of mower. Not under anti–scalp roller brackets.

Lower mower to the 1-1/2” (38 mm)

height-of-cut position (Fig. 42).

7. Tighten nut until the next set of slots line up

with the hole in the shaft (Fig. 41).

8. Replace cotter pin.

Figure 41

1. Slotted

2. T

wo threads or less

showing

Nut

Hole in threaded shaft

4. W

asher (if needed)

5. Slot



m–4122

Figure 42

1. Transport

position

1-1/2” (38 mm) height-of-cut

6. Loosen bottom chain bolt in slot at rear of deck.

Repeat for opposite side. (Fig. 43).

Note: Do not loosen front chain hardware.

7. Loosen front and rear locking nut on either side

of front swivel. Loosen until front chains are loose and deck is supported by blocks. Repeat for opposite side. (Fig. 43).

Maintenance

Note: When hardware is loose, deck will

rotate the lift handle up out of position.

8. When hardware is loosened, remaining tension

in the large support springs will tend to rotate the deck lift handle up, out of the 1–1/2” position. Press down on the rear deck support arm to firmly return the deck lift handle to the 1–1/2” position (Fig. 43).

Note: Do not push on deck lift handle.

9. While continuing to press down on rear deck

support arm, take the slack out of the rear chain and tighten hardware at the bottom (Fig. 43). Downward pressure may now be released. Repeat for opposite side.

10. Adjust front swivel using rear locking nut until

the front chain is tight and front of deck is still touching block. Tighten front locking nut. Repeat for opposite side.

12. Raise deck to 3 inch height of cut and measure

actual height from blade tips to ground. Height of cut for the front blade tips should be

3.00 ±.125 (76mm ± 3mm). Height of cut for rear blade tips should be 3.25±.125 (83mm± 3mm).Readjust if needed.

Note: When checking blade tip heights make

sure blades are not bent and check blade pointing front to rear.

13. Install anti–scalp rollers for proper height-of-cut

and tighten securely. See Adjusting Anti Scalp Rollers on page 30.

14. Raise deck lift lever to the transport position,

(Fig. 42).

15. Adjust compression springs by turning the front

spring nuts so the distance between the two large washers is 10-1/4” (260 mm). Then tighten jam nut (Fig. 43).

Note: Make sure all hardware is tight.



Figure 43

1. Bottom

2. T

chain bolt

op chain bolt Front swivel 10-1/4” (260 mm) spring

compressed

Rear Locking Nut

Front Locking Nut

Rear Deck Support Arm

Front Spring Nut

Jam Nut

11. Recheck that blocks fit just snuggly under the

mower and that tension on all four chains are approximately equal.

Maintenance

Adjusting

Push Arms

1. To adjust push arms, loosen jam nut and rotate

ball joint counterclockwise, one turn at a time. (Fig. 44).

2. Adjust each side the same amount. Each push

arm should have a nominal length of 15–5/16” (389mm) (Fig. 44).

Note: Increase tension by lengthening the

push arms and decrease tension by shortening push arms.

1. Push

arm

15–5/16” (389 mm) nominal

Figure 44

m–3740

Jam nut Ball joint

Throttle

Lever Adjustment

The tension can be adjusted by adjusting the tightness of lever pivot bolt. Do this when needed.

1. Stop engine, remove ignition key.

2. Remove console from machine to gain access to

throttle lever.

3. Tighten nut and bolt. Test lever to your desired

tension (Fig. 45).

1 3 4 2 5 6 7



Figure 45

1. Pivot

4. T

Bolt Throttle Lever Belleville W

ab W

ashers

asher

5. Washer

6. Bracket

7. Nut

Maintenance

Clean

Remove grass build up under deck daily.

1. Position mower on a flat surface. Stop the

2. Raise deck to the transport position.

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

POTENTIAL HAZARD

Under Deck

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

stands.

• Mechanical or hydraulic jacks may not

support machine

WHAT CAN HAPPEN

• Weight of machine can cause hydraulic

jacks to fail and cause an injury.

HOW TO AV

OID THE HAZARD

• Use jack stands when supporting machine.

• Do not use hydraulic jacks.

Belt

Inspect all belts every 100 hours.

1. Check belts for cracks, frayed edges, burn marks

Inspection

or any other damage. Replace damaged belts.

Maintenance

Replacing

the Deck 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. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove belt covers over outside spindles.

3. Loosen outer nut on spring eye bolt (Fig. 46).

1. Outer

Nut Idler Pulley Idler Arm Spring Eye Bolt

Figure 46

op V

iew

5. Spring

9.375 ±.125

±.3 mm)

7. Deck

M-4197

(238 mm

Belt

POTENTIAL HAZARD

• Spring is under tension when installed.

WHAT CAN HAPPEN

• Stored spring energy can cause personal

injury.

HOW TO AV

OID THE HAZARD

• Do not remove spring from spring eye bolt.

5. Remove spring loaded idler pulley (Fig. 46).

6. Route new belt through idler arm (Fig. 46).

7. Reinstall idler pulley and route belt onto other

pulleys (Fig. 47).

8. Retighten outer nut on spring eye bolt (Fig. 46). Note: Check spring length. The spring should

measure 9.375” ± .125” (238 mm ±.3 mm) when installed. Adjust if it does not (Fig. 46).

9. Install belt covers over outside spindles.

4. Remove belt. Start at outside pulley and rotate

off (Fig. 47). Note: Dot not remove spring.

1. Deck

Idler Arm

Outside Pulley

Belt

Figure 47

op V

iew

4. Spring

M-4269

Idler Pulley

Maintenance

Replacing

the Pump Drive Belt

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

1. Remove deck belt first. See Replacing the Deck

Belt on page 55.

2. Remove bolt from clutch strap and unplug clutch

electrical wire. (Fig. 48).

3. Pull spring loaded idler to side. Remove traction

belt from the engine and hydro pump pulleys (Fig. 48).

4. Install new belt around engine and hydro pump

pulleys (Fig. 48).

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

Release pressure on spring loaded idler (Fig. 48).

6. Reinstall deck belt.

Replacing

the Grass Deflector

1. Stop the engine, set the parking brake, remove

the key and disconnect the spark plug wire(s) from the spark plug(s).

2. Remove the locknuts, bolts and springs holding

the deflector mounts to the pivot brackets (Fig. 49).

3. If the pivot brackets need to be replaced, remove

the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets. Make sure the carriage bolt heads are on the inside of the cutting unit (Fig. 49).

4. Install the deflector mounts onto the pivot

brackets with the bolts, springs and locknuts. Make sure the straight ends of the springs are positioned between the deflector mounts and the grass deflector (Fig. 49).

1. Clutch

2. Bolt

Strap

Clutch Electrical Wire

Figure 48

4. Belt

5. Idler

6. Clutch

5. Tighten the locknuts until they contact the pivot

brackets (Fig. 49).

IMPORTANT: The grass deflector must be spring-loaded in the down position. Lift the deflector up to test that it snaps to the full down position.



1. Bolt

2. Deflector

3. Spring

Cone Locknut

Mount

Figure 49

7. Locknut

m–2549

Pivot Bracket Carriage Bolt

Maintenance

Adjusting

Motion Controls

Adjusting Handle Neutral

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 Install Motion Control Levers on page 18.

1. Stop engine, remove ignition key and tilt seat

forward.

2. Begin with either the left or right motion control

lever. Move lever to the neutral (but not locked) position and pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on spring) (Fig. 51).

5. Apply slight rearward pressure on the motion control lever, turn the head of the adjustment bolt in the appropriate direction until lever is centered in neutral lock position (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 (Fig. 51).

6. Tighten nut and jam nut.

7. Repeat on opposite side of unit.

4 3

3. Check where lever is relative to notch in console

(should be centered allowing lever to pivot outward to the neutral lock position (Fig. 50).



Figure 50

1. Right

hand Motion Control

Lever (shown)

Nuetral Lockout Position

4. If adjustment is needed, loosen the nut against

the yoke (Fig. 51).



1. Clevis

2. Nut

4. Bolt

pin in slot

Nut– Left hand Thread

Figure 51

Pump rod

Double nuts

Jam Nut

2 7

Maintenance

Adjusting Hydraulic Pump Neutral

Note: Adjust handle neutral first. That has to

be correct before the following adjustment can be made.

POTENTIAL HAZARD

• Mechanical or hydraulic jacks may not

support machine.

WHAT CAN HAPPEN

• Weight of machine can cause hydraulic

jacks to fail and cause an injury.

HOW TO AV

OID THE HAZARD

• Use jack stands when supporting machine.

• Do not use hydraulic jacks.

1. This adjustment must be made with drive wheels

turning. First raise the frame and block up so drive wheels can rotate freely.

Note: The front nut of each rod has left–hand

threads.

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

parking brake. Refer to Starting and Stopping the Engine, page 25.

6. Adjust pump rod length by rotating double nuts

on rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 51).

7. Move motion control lever forward and reverse,

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

Note: Motion control lever must be in neutral

while making any adjustments.

8. Open throttle to fast. Make sure wheel remains

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

9. Repeat on opposite side of unit. T

against ball joints.

ighten locknuts

POTENTIAL HAZARD

• Engine must be running so motion control

adjustment can be performed.

WHAT CAN HAPPEN

• Contact with moving parts or hot surfaces

may cause personal injury.

HOW TO AV

OID THE HAZARD

• Keep hands, feet, face, clothing and other

body parts away from rotating parts, muffler and other hot surfaces.

2. Slide seat forward, disconnect prop rod and tilt

seat fully forward.

3. Disconnect electrical connector from the seat safety switch. Temporarily across terminals in the wiring harness connector.

4. Loosen locknut at ball joint on pump control rod (Fig. 51).

install a jumper wire

POTENTIAL HAZARD

• Electrical system will not perform proper

safety shut off with jumper wire installed.

WHAT CAN HAPPEN

• Contact with moving parts may cause

personal injury.

HOW TO AV

• Remove jumper wire from wir

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

OID THE HAZARD

e harness

• Never operate this unit with jumper install

and seat switch by passed.

10. Shut off unit. Remove jumper wire from wire

harness connector and plug connector into seat switch.

11. Reinstall prop rod and lower seat.

Maintenance

Adjustment

Parking Brake

Check parking brake for proper adjustment.

1. Disengage brake lever (lever down).

2. Measure the length of the spring. Measurement

should be 2.75” (70 mm) between washers (Fig. 52).

3. If adjustment is necessary, loosen the jam nut

below the spring and tighten the nut directly below the yoke (Fig. 52). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on

unit.

opposite

side of

4. Turn nuts clockwise to shorten spring length and

turn counter–clockwise to lengthen the spring.

5. Engage parking brake, lever up.

6. Measure the distance between the trunnion roller

and the collar on brake rod . Measurement should be 3/16”–1/4” (5–7 mm) (Fig. 52).

Fuse

Service Interval/Specification

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

Fuse: Main F1–20 amp, blade-type

Alternator F2–20 amp, blade-type

1. Raise the seat to gain access to fuse holder

(Fig. 53).

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

(Fig. 53).

7. If adjustment is necessary, loosen the jam nut

directly below the yoke. Turn the bottom adjusting nuts until the correct measurement is obtained (Fig. 52). Tighten jam nut at yoke

1. Brake

lever Spring 2.75” (70 mm) Adjusting nuts Collar on brake rod

Figure 52

7. Trunion

3/16”–1/4’ (5–7 mm) Jam nut and yoke

M-4120

1. Main-20

amp

Figure 53

m–3653

Alternator-20 amp

Maintenance

Battery

Check the electrolyte level in the battery every 25 hours. Always keep the battery clean and fully charged. Use a paper towel to clean the battery case. If the battery terminals are corroded, clean them with a solution of four parts water and one part baking soda. Apply a light coating of grease to the battery terminals to prevent corrosion.

Voltage: 12 v

Checking Electrolyte Level

1. Open covers to see into the cells. The electrolyte

must be up to the lower part of the tube (Fig. 54). Do not allow the electrolyte to get below the plates. (Fig. 54).

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

of distilled water; refer to Adding Water to the Battery.

Adding Water to the Battery

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

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

2. Lift off the filler caps (Fig. 54).

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 54).

IMPORTANT: Do not overfill the battery because electr sever

e corr

olyte (sulfuric acid) can cause

osion and damage to the chassis.

4. Press the filler caps onto the battery.

Charging the Battery

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

1. Filler

caps

Lower part of tube

1. Check the electrolyte level; refer to Checking

Electrolyte Level, page 60.

1262

2. Remove the filler caps from the battery and

Figure 54

3. Plates

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

POTENTIAL HAZARD

• Charging the battery pr

oduces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

Maintenance

Waste

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

Disposal

Mercury Tilt Switch

The tilt switch on this unit is located under the seat. Tilt 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

Several 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 insure 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.

states have passed laws concerning the

POTENTIAL HAZARD

• The mercury contained in the tilt switch is

poisonous.

WHAT CAN HAPPEN

• Exposure to mer

illness.

HOW TO AV

cury can cause sever

OID THE HAZARD

• Never attempt to open or repair the tilt

switch.

• Avoid contact with the mercury.

Maintenance

Wiring

Diagram

 

Maintenance

Cleaning

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

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

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

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

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

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

page 40.

4. Grease and oil the machine; refer to Greasing

and Lubrication, page 46.

and Storage

void excessive

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 Fuel Tank, page 45. D. Restart engine and run it until it stops. E. Choke or prime the engine. Start and run

engine until it will not start. Operate primer,

if equipped on machine, several times to

ensure no fuel remains in primer system. F. Dispose of fuel properly. Recycle as per

local codes.

IMPORTANT: Do not store stabilizer/conditioned gasoline over 90 days.

G. Run engine to distribute conditioned fuel

through the fuel system (5 minutes). H. Stop engine, allow to cool and drain the

fuel tank; refer to Fuel Tank, page 45.

5. Change the crankcase oil; refer to Engine Oil,

page 42.

6. Change the hydraulic fluid; refer to Hydraulic

System, page 48.

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

page 50.

8. Charge the battery; refer to Battery page 60.

9. Prepare the machine for storage when non–use

occurs over 30 days. Prepare machine for storage as follows.

A. Add a petroleum based

stabilizer/conditioner to fuel in the tank. Follow mixing instructions from stabilizer manufacture. (1 oz. per gallon). 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.

I. Restart engine and run until it stops.

Repeat, on “CHOKE” until engine will not

restart. J. Dispose of fuel properly. Recycle as per

local codes. Note: Do not store stabilizer/conditioned

gasoline over 90 days.

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

condition; refer to Spark Plug, page 44. 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).

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

Repair or replace any part that is damaged or defective.

12. Paint all scratched or bare metal surfaces. Paint

is available from your Authorized Service Dealer.

Maintenance

13. Clean any dirt and chaff from the top of the

mower.

14. Scrape any heavy buildup of grass and dirt from

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

15. Check the condition of the blades. Refer to

Cutting Blades on page 37.

16. Check the condition of the drive and deck belts.

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

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

Troubleshooting

PROBLEM

Starter does not crank

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

POSSIBLE CAUSES

Blade control (PT ENGAGED.

Parking brake is not on.

Operator is not seated.

Battery is dead.

Electrical connections are corroded or loose.

Fuse is blown.

Relay or switch is defective.

Fuel tank is empty

Fuel valve turned of

Choke is not ON.

Air cleaner is dirty

Spark plug wires are loose or disconnected.

O) is

. 4.

CORRECTIVE ACTION

Move blade control (PT DISENGAGED.

Set parking brake.

Sit on the seat.

Charge the battery

Check electrical connections for good contact.

Replace fuse.

Contact Authorized Service Dealer.

Fill fuel tank with gasoline.

Open fuel valve.

Move choke lever to ON. Clean or replace air cleaner

element.

Install wires on spark plug.

O) to

Engine loses power

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

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Air cleaner is dirty

Oil level in crankcase is low

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

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

6. V

ent in fuel cap is closed.

Dirt in fuel filter

Dirt, water fuel system.

. 7.

, or stale fuel is in

. 2.

. 7.

, or stale fuel is in

. 3.

Install new spark plugs.

Replace fuel filter Contact Authorized Service

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

cooling fins and air passages.

Install new spark plugs.

Open vent in fuel cap. Replace fuel filter Contact Authorized Service

Dealer.

, correctly gapped

Troubleshooting

PROBLEM

Engine overheats.

Abnormal vibration.

Machine does not drive.

Abnormal vibration.

POSSIBLE CAUSES

Engine load is excessive.

Oil level in crankcase is low

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

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

1. T

raction belt is worn, loose or

broken.

2. T

raction belt is of

Hydro fluid level low

Engine mounting bolts are loose.

f pulley

. 2.

, idler

. 2.

. 3.

CORRECTIVE ACTION

Reduce ground speed. Add oil to crankcase.

Remove obstruction from cooling fins and air passages.

1. T

ighten engine mounting

bolts.

2. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Add hydro fluid to reservoir

1. T

ighten engine mounting

bolts.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

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

Blade mounting bolt is loose.

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

Blade spindle bent.

, idler

2. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Install new cutting blade(s).

5. T

ighten blade mounting bolt.

6. T

ighten engine mounting

bolts.

7. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Troubleshooting

PROBLEM

Uneven cutting height.

Blades do not rotate.

POSSIBLE CAUSES

Blade(s) not sharp.

Cutting blade(s) is/are bent.

Mower is not level.

Gage wheel not set correctly

Underside of mower is dirty

6. T

ire pressure is incorrect.

Blade spindle bent.

Drive belt is worn, loose or broken.

Drive belt is of

Deck belt is worn, loose or broken.

f pulley

. 2.

CORRECTIVE ACTION

Sharpen blade(s).

Install new cutting blade(s).

Level mower from side-to-side and front-to-rear.

Adjust gage wheel height.

Clean the underside of the mower.

Adjust tire pressure.

Contact Authorized Service Dealer.

Install new drive belt.

Install drive belt and check adjusting shafts and belt guides for correct position.

Install new deck belt.

LCE

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       

Customers who have purchased TORO products exported from the United States or Canada should contact their TORO DisĆ tributor (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 The Toro Company.

Rev

9/30/98

ur-

Toro 74170 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual