Toro 74178 Operator's Manual

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Page 1

Form No. 3326–670

Z150

Z–Master with 52 SFS Side Discharge Mower

Model No. 74178—210000001 & Up

Operator ’s Manual

Domestic English (EN)

Page 2

Warning

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

Because in some areas there are local, state, or federal regulations requiring that a spark arrester be used on the engine of this mower, a spark arrester is incorporated with the muffler assembly.

Important This engine is equipped with a spark

arrester muffler. It is a violation of California Public Resource Code Section 4442 to use or operate this engine without a spark arrester muffler on any forest–covered, brush–covered or grass–covered land. Other states or federal areas may have similar laws.

This spark ignition system complies with Canadian ICES-002.

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

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

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

Contents

Page

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

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

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

Toro Mower Safety 5. . . . . . . . . . . . . . . . . . . . . . .

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

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

Gasoline and Oil 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 12. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 12. . . . . . . . . . . . . . . .

Filling the Fuel Tank 12. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 12. . . . . . . . . . . . . . . . . . . .

Assembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Drive Wheels 13. . . . . . . . . . . . . . . . . . . . . .

Tire Pressure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Seat Retaining Rod 13. . . . . . . . . . . . . . . . . .

 2000 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Install Motion Control Levers 14. . . . . . . . . . . . . . .

Activate the Battery 14. . . . . . . . . . . . . . . . . . . . . . .

Install Battery 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System 16. . . . . . . . . . . . . . . . . . . . . . . . .

Greasing the Bearings 16. . . . . . . . . . . . . . . . . . . . .

Check the Leveling of Mower Deck 17. . . . . . . . . .

Check Side Discharge Chute 17. . . . . . . . . . . . . . . .

Check Engine Oil Level 17. . . . . . . . . . . . . . . . . . . .

Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 17. . . . . . . . . . . . . . . . . . . . . . . .

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

Parking Brake 18. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Testing the Safety Interlock System 19. . . . . . . . . .

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

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

Instruments 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tanks 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Side Discharge 23. . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting Machines 23. . . . . . . . . . . . . . . . . . . .

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

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

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

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

Cutting Blades 26. . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Spark Arrester 32. . . . . . . . . . . . . . . .

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

Greasing the Bearings 32. . . . . . . . . . . . . . . . . . . . .

Hydraulic System 33. . . . . . . . . . . . . . . . . . . . . . . . .

Tire Pressure 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Castor Pivot Bearing Adjustment 35. . . . . . . . . . . .

Wheel Hub Slotted Nut 35. . . . . . . . . . . . . . . . . . . .

Mower Leveling 36. . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Push Arms 37. . . . . . . . . . . . . . . . . . . . . .

Throttle Lever Adjustment 37. . . . . . . . . . . . . . . . .

Clean Under Deck 37. . . . . . . . . . . . . . . . . . . . . . . .

Belt Inspection 37. . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Deck Belt 37. . . . . . . . . . . . . . . . . . .

Page

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Replacing the Pump Drive Belt 38. . . . . . . . . . . . . .

Adjusting Motion Controls 39. . . . . . . . . . . . . . . . .

Adjusting Parking Brake 41. . . . . . . . . . . . . . . . . . .

Fuse 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Waste Disposal 42. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch 42. . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch Disposal 42. . . . . . . . . . . . . . .

Replacing the Grass Deflector 43. . . . . . . . . . . . . . .

Wiring Diagram 44. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 45. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 48. . . . . . . . . . . . .

Page

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.

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.

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 at the location shown in Figure 1.

m-3648

Figure 1

1. Model and serial number plate

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

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.

Determine the left and right side of the machine from the normal operating position.

Safety

This machine meets or exceeds 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 noncompliance of this machine.

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

Safe Operating Practices

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

Training

• Read the Operator ’s Manual and other training

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

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• 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.

• Never operate with the PTO shield, or other guards not

securely in place. Be sure all interlocks are attached, adjusted properly, and functioning property.

• 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.

• The owner/user can prevent and is responsible for

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

Preparation

• Evaluate the terrain to determine what accessories and

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

• Wear appropriate clothing including hard hat, safety

glasses and 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.

• 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.

• 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.

• 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

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

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

engaged before starting engine. Only start engine from the operator ’s position. Use 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’s stability. Use caution while operating near drop–offs.

• Slow down and use caution when making turns and

when changing directions on slopes.

• Never raise deck with the blades running.

• Disengage drives, lower implement, set parking brake,

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

• Clean grass and debris from cutting units, drives,

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

• Let engine cool before storing and do not store near

flame.

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

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

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• Carefully release pressure from components with

stored energy.

• Disconnect battery or remove spark plug wire before

making any repairs. Disconnect the negative terminal

first and the positive last. Reconnect positive first and

negative last.

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

wear gloves, and use caution when servicing them.

Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine

running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before

connecting or disconnecting from battery. Wear

protective clothing and use insulated tools.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged

decals.

Toro Mower Safety

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.

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

General Operation

• Allow only responsible adults who are familiar with

the instructions to operate the machine.

• Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

• Do not mow in reverse unless absolutely necessary.

Always look down and behind before and while

backing.

• Be aware of the mower discharge direction and do not

point it at anyone. Do not operate the mower without

either the entire grass catcher or the guard in place.

• Slow down before turning. Sharp turns on any terrain

may cause loss of control.

• Turn off blades when not mowing.

• Keep hands, feet, hair and loose clothing away from

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

• Stop the engine before removing the grass catcher or

unclogging the chute.

• Mow only in daylight or good artificial light.

• Watch for traffic when operating near or crossing

roadways.

• Do not touch equipment or attachment parts which

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

• Before operating a machine with ROPS (roll over

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

• Use only Toro-approved attachments. Warranty may

be voided if used with unapproved attachments.

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.

• 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. Tall grass can hide obstacles.

• 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.

• 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.

• When operating a machine with ROPS (roll over

protection) always use seat belt.

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• 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 mow slopes exceeding 15 degrees.

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

and gradually downhill, if possible.

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

The machine could suddenly turn over if a wheel goes over the edge of a cliff or ditch, or if an edge caves in.

• Do not mow on wet grass. Reduced traction could

cause sliding.

• Do not 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.

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 use your hands.

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Slope Chart

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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.

Top of Console Under Seat

(Part No. 103–0315)

On Control Panel

(Part No. 103–0167)

On Right Side of Height-of-Cut

Plate

(Part No. 1–653140)

Below Center Of Console

(Part No. 103–0262)

On Left Side of Height-of-Cut

Plate

(Part No. 1–653147)

Lower Left of Console

(Part No. 98-4387)

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On Top Left Side of Frame

(Part No. 1–633818)

On Tilt Switch

(Part No. 1–643401)

On Top of Hydraulic

Reservoir

(Part No. 1–523552)

Under Footrest

(Part No. 99-3924)

On Frame Under Seat

(Part No. 1–603845)

On Frame Near Muffler

(Part No. 65-2690)

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On Right Side of Mower

(Part No. 661340)

On Left Side of Mower

(Part No. 438480)

Under Belt Cover (3)

Under Footrest (1)

(Part No. 98-5954)

On Top Center of Mower

(Part No. 993943)

99–3943

On Left Front of Mower

(Part No. 937818)

On Deflector

(Part No. 549220)

On Top of Mower in Center

(Part No. 983798)

(2) On Belt Covers

(Part No. 675360)

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Gasoline and Oil

Recommended Gasoline

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

Important Never use methanol, gasoline containing

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

Danger

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

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

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

• 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.

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle

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

• When practical, remove gas–powered

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

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used,

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

Warning

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

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

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

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

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel

system, which causes hard starting

Important Do not use fuel additives containing

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

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

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

Filling the Fuel Tank

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

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

Add unleaded regular gasoline to both fuel tanks, until the level is 1/4 to 1/2 inch (6 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.

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

that may have spilled.

Check Engine Oil Level

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

Page 13

Assembly

Loose Parts

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

Description Qty. Use

Rear Wheels 2 Install wheels to traction unit 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’s Manual Engine Operator’s Manual Parts Catalog

Registration card 1 Fill out and return to Toro

1 1 1

1 1 4 4

2 1 1 1

Install seat rod

Install motion control levers

Read before operating machine

Install Drive Wheels

1. Uncrate mower.

2. Remove wheel bolts or nuts from rear wheel hubs.

3. Align holes. Mount drive wheels with the valve stem

to the outside of the traction unit.

4. Secure using wheel bolts or nuts provided. Torque to

95 ft-lbs (128 NM).

Tire Pressure

Check the air pressure in the front and rear tires (Fig. 2). Pressure: 13 psi (90 kPa)

m–1872

Figure 2

1. Valve stem

Install Seat Retaining Rod

1. Tilt seat up. Remove 5/16″ (8mm) locknut from bolt

attaching seat retaining rod to seat frame (Fig. 3).

Page 14

2. Remove retaining rod from seat and insert the “L”

shaped end of the rod into the hole directly above the left–side hydraulic pump (Fig. 3).

3. 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. 3).

4. Tighten until snug, then loosen so the rod pivots freely.

m–3750

Figure 3

1. L end of retaining rod

2. Locknut 5/16″

3. Bolt 5/16-18 x 1″ (26 mm)

m–3751

Figure 4

1. Mounting plate

2. Bolt 3/8-18 x 1″ (26 mm)

3. Spring washer 3/8″

5. If the ends of the levers hit against each other, while in

the drive position (Fig 5) (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.

Install Motion Control Levers

1. 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. 4).

2. 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. 4).

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

slots on the lever mounting plate and tighten until snug.

4. Align the front\rear position of the levers, with each

other, in the neutral position. Loosen hardware and adjust by sliding/tilting the lever(s) forward or backward until properly aligned (Fig. 4).

Figure 5

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.

Page 15

Danger

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

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

2. Place battery on a level surface.

3. 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. 6).

m–1262

Figure 6

1. Filler caps

2. Electrolyte

3. Lower part of the tube

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

charger to the battery posts (Fig. 7). Charge the battery

at a rate of 4 amperes or less for 4 hours (12 volts).

m–1254

Figure 7

1. Positive post

2. Negative post

3. Charger red (+) wire

4. Charger black (–) wire

Warning

Charging battery produces gasses that can explode and cause serious injury.

• Keep cigarettes, sparks and flames away from

battery.

• Make sure the ignition switch is off.

• Ventilate when charging or using battery in an

enclosed space.

5. When the battery is fully charged, disconnect the

charger from the electrical outlet then from the negative and positive battery posts (Fig. 7).

6. Slowly pour electrolyte into each cell until the level is

once again up to the “UPPER” line on the battery case (Fig. 6) and install covers.

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

battery.

Install Battery

1. Position battery in tray with terminal posts toward the

engine (Fig. 8).

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. 8).

Page 16

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

6 7

battery post.

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

out of the system and warm fluid.

6. Secure battery with J-bolts, hold down clamp and (2)

1/4″ washers and (2) 1/4″ wing nuts (Fig. 8).

7. Position drain tube away from belts and other parts to

prevent corrosion.

9 5

m–3752

Figure 8

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

5. Ground wire

6. Bolt 1/4-20 x 3/4″ (19 mm)

7. Washer 1/4″

8. Locknut 1/4″

9. Battery clamp

10. J-bolts

11. Wing nut 1/4″

12. Drain tube

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)

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. 9).

7. Install cap on filler neck.

M-4280

Figure 9

1. Cap

2. Baffle

3. Fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

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

brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 9).

3. Remove cap from filler neck. Look inside to check if

there is fluid in the reservoir (Fig. 9).

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

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

Greasing the Bearings

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.

Page 17

1. Grease the fittings on the three spindle bearings.

Grease until it comes out lower seals (Fig. 10).

Caution

Figure 10

1. Spindles

Check the Leveling of Mower Deck

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

M-4159

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

Wear hearing protection when operating this machine.

Figure 11

1. Caution 2. Wear hearing protection

Controls

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

Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 36.

Check Side Discharge Chute

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

Check Engine Oil Level

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

Operation

Think Safety First

Please carefully read all the safety instructions on pages 3–9. Knowing this information could help you, your family, pets or bystanders avoid injury.

The use of protective equipment, such as but not limited to, for eyes, ears, feet and head is recommended.

1. Ignition switch

2. Motion control lever

3. Parking brake lever

4. Throttle

5. Choke

Figure 1

6. Power take off (PTO)

7. Height-of-Cut lever

8. Fuel cap

9. Hourmeter

10. Fuel shut-off valve

m–4200

Page 18

Parking Brake

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

Important Do not park on slopes unless wheels are

chocked or blocked.

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.

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

before starting a cold engine.

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

When engine starts, release key.

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. 4). 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.

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”.

m–4121

Figure 2

1. Parking brake—ON 2. Parking brake—OFF

Starting and Stopping the Engine

Starting

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

neutral locked position.

Figure 3

1. PTO—On

2. PTO—Off

Figure 5

1. Fast

2. Slow

m–4201

m–2720

m–2719

Figure 4

1. Choke—On

2. Choke—Off

m–4268

Figure 6

1. Off

2. Run

3. Start

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

Brake, page 18.

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

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

starting a cold engine.

Note: A warm or hot engine may require choking. After engine starts, move choke control to “OFF” position.

Stopping

1. Move the throttle lever to “SLOW” (Fig. 5).

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

3. Turn the ignition key to “OFF” (Fig. 6).

Page 19

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.”

The Safety Interlock System

Caution

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.

Important Make sure fuel shut off valve is closed

before transporting or storing machine, as fuel leakage may occur.

Operating the Power Take 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. Place throttle to the fast position.

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

(Fig. 7).

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

• You are sitting on the seat

• The parking brake is on “ENGAGED”

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

• The motion control levers are in neutral locked

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.

Figure 7

1. PTO—Off 2. PTO—On

Disengaging the PTO

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

position (Fig. 7).

m–4201

Testing the Safety Interlock System

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

1. Sitting on the seat, “ENGAGE” 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.

Page 20

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.

Driving Forward or Backward

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

Caution

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

• Use caution when making turns.

• Slow the machine down before making sharp

turns.

Forward

1. Release the parking brake; refer to Releasing the

Parking Brake, page 18.

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

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

forward (Fig. 8).

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. 8).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 8).

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.

m–2715

Figure 8

1. Motion control lever—neutral lock position

2. Center unlock position

3. Forward

4. Backward

Backward

1. Move levers to the center, unlocked position.

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

rearward (Fig. 8).

To go straight, apply equal pressure to both motion control levers (Fig. 8).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 8).

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

Caution

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

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

Page 21

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.

m–4202

Figure 9

1. Hour meter

Fuel Tanks

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

(also the 4-1/2″ (114 mm) cutting height position) (Fig. 11).

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

height-of-cut bracket (Fig. 11).

3. Select hole in height-of-cut bracket corresponding to

the height-of-cut desired, and insert clevis pin (Fig. 11).

4. Secure clevis pin with hairpin cotter (Fig. 11).

The unit has two fuel tanks, located on the left and right sides. Each tank connects to the fuel shut off valve in the control panel. From there a common fuel line leads to the engine (Fig. 10).

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.

Figure 10

1. Shut-off valve

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.

m-4122

Figure 11

1. Height-of-cut lever

2. Clevis pin

5. Lower height–of–cut lever onto clevis pin.

3. Hairpin cotter

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. 12).

Note: Do not remove the wheel nut and washer (Fig. 12).

3. Select hole so gage wheel is positioned to the nearest

corresponding height-of-cut desired (Fig. 12).

4. Reinstall the stud nut and washer (Fig. 12).

5. Repeat adjustment on other gage wheels.

Page 22

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. 14).

m–4167

Figure 12

1. Gage wheel

2. Stud

3. Washer

4. Nut

5. Wheel nut and washer. Do not remove.

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. 13).

3. Select hole so gage wheel is positioned to the nearest

corresponding height-of-cut desired (Fig. 13).

Note: Do not adjust rollers to support the deck.

4. Reinstall the bolt, center rollers and nut (Fig. 13).

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

to lock in position.

m–3655

Figure 14

1. Adjustment lever

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

To Push the Machine

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

ignition key to “OFF” to stop the engine.

1. Center rollers and spacer

2. Nut

Figure 13

3. Bolt

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

push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 15).

Important Do not rotate by–pass valves more than 1

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

To Operate the Machine

m–4124

1. Turn the by-pass valves in to operate (Fig. 15). Note: The machine will not drive unless by-pass valves

are turned in.

Page 23

1. By-pass valve

Figure 15

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 to towing vehicle with safety chains.

Warning

Side Discharge

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

Danger

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

• Never remove the grass deflector from the

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

• Never put your hands or feet under the mower.

• Never try to clear discharge area or mower

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

Transporting Machines

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

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

Do not drive machine on a public street or roadway.

Loading Machines

Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit. 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.

Page 24

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.

Warning

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

• Use extreme caution when operating a unit on a

ramp.

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

individual ramps for each side of the unit.

• If individual ramps must be used, use enough

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

• Do not exceed a 15 degree angle between ramp

and ground or between ramp and trailer or truck.

• Avoid sudden acceleration while driving unit up

a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing unit

down a ramp to avoid tipping backward.

Tips for Mowing Grass

Mow at Correct Intervals

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

Cutting Speed

To improve cut quality, use a slower ground speed.

Avoid Cutting Too Low

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

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.

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.

Mowing Direction

When Stopping

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

Keep the Underside of the Mower Clean

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

Blade Maintenance

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

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

Page 25

Maintenance

Recommended Maintenance Schedule

Maintenance Service

Interval

After First Use

Each Use

Every 5 Hours

Every 25 Hours

Maintenance Procedure

• Check hydraulic fluid level

• Change engine oil

• Change hydraulic filter

• Check engine oil level

• Check safety system

• Clean cooling systems

• Clean mower housing

• Check cutting blades

• Grease blade spindle bearings

• Check hydraulic fluid level

• Grease chassis

• Oil linkage bushings

• Service foam air cleaner

• Service paper air cleaner

• Check belts for wear/cracks

• Check battery electrolyte

• Check tire pressure

• Idler pulley pivot

Every 50 Hours • Service the spark arrester

Every 100 Hours

• Change engine oil

• Replace paper air cleaner

• Check spark plug(s)

• Check hydraulic lines

Every 200 Hours

• Change oil filter

• Change hydraulic filter

• Replace fuel filter

Every 500 Hours or at

Storage

• Adjust castor pivot

• Adjust wheel hub slotted nut

• Perform all maintenance procedures listed above before storage

Before Storage

• Drain gasoline

• Charge battery, disconnect cables

• Paint chipped surfaces

More often in dusty, dirty conditions

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

Page 26

Caution

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

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

Cutting Blades

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

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

Danger

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

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing the Blades

Inspecting the Blades

1. Inspect the cutting edges (Fig 16). If the edges are not

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

2. Inspect the blades, especially the curved area (Fig. 16).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 16), immediately install a new blade.

m–151

1. Cutting edge

2. Curved area

Figure 16

3. Wear/slot forming

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).

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. 17). Measure from a level surface to the cutting edge of the blades (Fig. 18). Note this dimension.

Page 27

Front

Figure 17

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

Figure 18

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 2 above. The difference between the dimensions obtained in steps 2 and 3 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, page 27.

Warning

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

m–1078

m–2539

M-4226

Figure 19

1. Sail area of blade

2. Blade

3. Spring disk

4. Blade bolt

Sharpening the Blades

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

the blade (Fig. 20). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 20

1. Sharpen a t original angle

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

balancer (Fig. 21). 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. 19). Repeat this procedure until the blade is balanced.

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

Removing the Blades

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

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, spring disk and blade from the spindle shaft (Fig. 19).

Figure 21

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 19).

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. 19). Torque the blade bolt to 85–110 ft-lb (115–150 Nm).

m–1855

Page 28

Air Cleaner

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

Paper Element: Replace after every 100 operating hours. Note: Service the air cleaner more frequently (every few

hours) if operating conditions are extremely dusty or sandy.

Removing the Foam and Paper Elements

1. 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. Unscrew the knob and remove the air cleaner cover (Fig. 22).

Cleaning the Foam and Paper Elements

1. Foam Element

A. Wash the foam element in liquid soap and warm

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

B. Dry the element by squeezing it in a clean cloth

(do not wring).

C. Put oil on the element (Fig. 23). Squeeze the

element to distribute the oil.

Important Replace the foam element if it is torn or

worn.

m–1213

Figure 23

1. Foam element 2. Oil

2. Paper Element

m–4086

Figure 22

1. Knob

2. Air cleaner cover

3. Cover nut

4. Cover

5. Foam element

6. Paper element

7. Rubber seal

8. Air cleaner base

9. Knob gasket

10. Spitback cup

11. Spitback gasket

3. Carefully slide the foam element off the paper element

(Fig. 22).

4. Unscrew the cover nut and remove the cover and paper

element (Fig. 22).

A. Lightly tap the element on a flat surface to remove

dust and dirt (Fig. 24).

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.

m–1213

Figure 24

1. Paper element 2. Rubber seal

Page 29

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.

4. Slide the oil dipstick fully into the filler tube, do not

thread onto tube (Fig. 25). Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark.

1. Carefully slide the foam element onto the paper air

cleaner element (Fig. 22).

2. Place the air cleaner assembly onto the air cleaner base

(Fig. 22).

3. Install the air cleaner cover and secure with cover nut

(Fig. 22).

Engine Oil

Change oil:

• After the first 5 operating hours.

• After every 100 operating hours.

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

Oil Type: Detergent oil (API service SG or SH) Crankcase Capacity: w/filter, 2.1 qt. (2 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

Important Do not overfill the crankcase with oil

because the engine may be damaged.

m–4090 m–3219

1. Oil dipstick

2. Filler tube

Figure 25

3. Metal end

Changing/Draining Oil

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

the oil so it drains better.

10W–30, 10W–40

5W–20, 5W–30

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

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. 25) so dirt cannot

fall into the filler hole and damage the engine.

3. Unscrew the oil dipstick and wipe the metal end clean

(Fig. 25).

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

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

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

cap (Fig. 26).

4. When oil has drained completely, install the drain cap. Note: Dispose of the used oil at a certified recycling

center.

Page 30

5. Install the replacement oil filter to the filter adapter.

Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 27).

6. Fill the crankcase with the proper type of new oil;

refer to Changing/Draining Oil, page 29.

m–4090

Figure 26

1. Oil drain cap

5. Slowly pour approximately 80% of the specified

amount of oil, page 29, into the filler tube (Fig. 25). Now check the oil level; refer to Checking Oil Level, page 29. Slowly add additional oil to bring to “FULL” mark on dipstick.

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 29.

2. Remove the old filter and wipe the filter adapter

(Fig. 27) gasket surface.

Spark Plug

Check the spark plug(s) after every 200 operating hours. Make sure the air gap between the center and side electrodes is correct before installing the spark plug. Use a spark plug wrench for removing and installing the spark plug(s) and a gapping tool/feeler gauge to check and adjust the air gap. Install a new spark plug(s) if necessary.

Type: Champion RC12YC (or equivalent) Air Gap: 0.030 in. (0.76 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. 28). Now

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

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

3. Pour new oil of the proper type in through the center

hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by filter material.

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

the replacement filter (Fig. 27).

m–1256

Figure 27

1. Oil filter

2. Gasket

3. Adapter

m–4089

Figure 28

1. Spark plug wire 2. Spark plug

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 29). If you

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

Important Never clean the spark plug(s). Always

replace the spark plug(s) when it has a black coating, worn electrodes, an oily film, or cracks.

Page 31

2. Check the gap between the center and side electrodes

(Fig. 29). Bend the side electrode (Fig. 29) if the gap is not correct.

1. Center electrode insulator

2. Side electrode

Figure 29

3. Air gap (not to scale)

0.030 in .

(0.76 mm)

m–3215

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 20 ft-lb (27 N.m).

3. Push the wire(s) onto the spark plug(s) (Fig. 28).

Figure 30

1. Filter 2. Hose clamp

Fuel Tank

Draining The Fuel Tank

Danger

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

m–4088

Fuel Filter

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

Replacing the Fuel Filter

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

1. Disengage the 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. 30).

4. Remove the filter from the fuel lines.

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

the filter (Fig. 31).

6. Open fuel shut-off valve on console.

• Drain gasoline from the fuel tank when the

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

• Never smoke when draining gasoline, and stay

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

1. Park the machine on a level surface, to 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. 31).

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

the fuel line away from the fuel filter (Fig. 31).

4. Pull the fuel line off fuel filter (Fig. 31).

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

gasoline to drain into a gas can or drain pan (Fig. 31).

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

Page 32

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

clamp close to the fuel filter to secure the fuel line (Fig. 31).

Figure 31

1. Fuel shut-off valve

2. Fuel filter

3. Hose clamp

4. Fuel line

Servicing the Spark Arrester

Where to Add Grease

Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 32).

m–4088

Figure 32

Inspect the spark arrester every 50 hours for damage, such as holes in the screen, and for build-up on the screen. If it is damaged, replace it with a new spark arrester. If it is dirty, remove it and clean the screen with a wire brush and/or soak it in solvent.

Greasing and Lubrication

Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 32). 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.

4. Wipe up any excess grease.

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

bearing.

3. Remove grease zerk in hole. Reinstall hex plug and

cap.

Greasing the Bearings

The cutting unit must be lubricated regularly; refer to the Recommended Maintenance Schedule on page 25. 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. 33).

3. Grease the idler pulley pivot (Fig. 33).

4. Grease the fittings on the push arms (Fig. 33).

Page 33

Figure 33

3. Remove cap from filler neck. Look inside to check if

there is fluid in the reservoir (Fig. 34).

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. 34).

7. Install cap on filler neck.

m–4159

Where to Add Light Oil or Spray Lubrication

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

• Seat switch actuator.

• Brake handle pivot.

• Brake rod bushings.

• Motion control bronze bushings.

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. 34).

Figure 34

1. Cap

2. Baffle

3. Fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

m–4280

Page 34

Replacing the Hydraulic Filter

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.

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

wipe the filter adapter gasket surface clean (Fig. 35).

m–4117

Figure 35

1. Hydraulic filter

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

the replacement filter (Fig. 36).

5. Install replacement hydraulic filter onto the filter

adapter. Do not tighten.

6. Remove plastic bag from tank opening and allow filter

to fill with hydro fluid.

7. 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. 36).

m–1256

Figure 36

1. Hydraulic filter

2. Gasket

3. Adapter

8. Clean up any spilled fluid.

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

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

10.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 34.

11. Recheck level while fluid is warm. Add fluid to raise level to top of the baffle, if required. Do not over fill.

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.

Page 35

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.

Castor Pivot Bearing Adjustment

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

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

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

Tire Pressure

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. 38).

3. Tighten until spring washers are flat and then back off

a 1/4 turn to properly set the preload on the bearings (Fig. 38).

Important Make sure spring washers are installed

correctly as shown in Figure 38.

m–4640

Figure 38

1. Spring washers

2. Lock nut

3. Dust cap

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

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

m–1872

Figure 37

1. Valve stem

Wheel Hub Slotted Nut

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

(169.5 Nm).

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 Nm) (Fig. 39).

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

edge of hole. Two threads or less should be showing (Fig. 39).

5. If more than two threads are showing remove nut and

install washer between hub and nut (Fig. 39).

6. Torque the slotted nut to 125 ft-lbs (169.5 Nm)

(Fig. 39).

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

hole in the shaft (Fig. 39).

Page 36

8. Replace cotter pin.

m-4638

Figure 39

1. Slotted n u t

2. Two threads or less showing

3. Hole in threaded shaft

4. Washer (if needed)

5. Slot

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. 40). 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. 41).

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

Repeat for opposite side (Fig. 41).

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. 41).

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. 41).

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. 41). 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.

5. Place two 1-3/8″ (35 mm) thick blocks under rear left and right lower edge of mower. Place one 1-3/4″ (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. 40).

m–4122

Figure 40

1. Transport position 2. 1-1/2″ (38 mm)

height-of-cut

m–4116

Figure 41

1. Bottom chain bolt

2. T op chain bolt

3. Front swivel

4. 10-1/4″ (260 mm) spring compressed

5. Rear locking nut

6. Front locking nut

7. Rear deck support arm

8. Front spring nut

9. Jam nut

11. Recheck that blocks fit just snuggly under the mower and that tension on all four chains are approximately equal.

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 inches (76 mm ± 3 mm). Height of cut for rear blade tips should be

3.25±.125 inches (83 mm± 3 mm). Readjust if needed.

Note: When checking blade tip heights make sure blades are not bent and check blade pointing front to rear.

Page 37

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

tighten securely. See Adjusting Anti-Scalp Rollers on page 21.

14.Raise deck lift lever to the transport position (Fig. 40).

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. 41).

Note: Make sure all hardware is tight.

Adjusting Push Arms

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

joint counterclockwise, one turn at a time. (Fig. 42).

1. Adjust each side the same amount. Each push arm

should have a nominal length of 15-5/16″ (389mm) (Fig. 42).

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

1 3 4 2 5 6 7

m-4643

Figure 43

1. Pivot bolt

2. Throttle lever

3. Belleville washers

4. Tab washer

5. Washer

6. Bracket

7. Nut

Clean Under Deck

Remove grass build up under deck daily.

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. Raise deck to the transport position.

m–3740

Figure 42

1. Push arm

2. 15-5/16″ (389 mm) nominal

3. Jam nut

4. 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 and adjust to desired tension (Fig. 43).

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

stands.

Danger

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

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Belt Inspection

Inspect all belts every 100 hours.

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

any other damage. Replace damaged belts.

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).

Page 38

2. Remove belt covers over outside spindles.

3. Loosen outer nut on spring eye bolt (Fig. 44).

Figure 44

Top View

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

5. Spring

6. 9.375±.125 (238 mm±.3 mm)

7. Deck belt

4. Remove belt. Start at outside pulley and rotate off

(Fig. 45).

Note: Dot not remove spring.

Caution

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

Do not remove spring from spring eye bolt.

m–4197

m–4159

Figure 45

Top View

1. Deck belt

2. Idler arm

3. Outside pulley

4. Spring

5. Idler pulley

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 37.

2. Remove bolt from clutch strap and unplug clutch

electrical wire (Fig. 46).

3. Pull spring loaded idler to side. Remove traction belt

from the engine and hydro pump pulleys (Fig. 46).

4. Install new belt around engine and hydro pump pulleys

(Fig. 46).

5. Remove spring loaded idler pulley (Fig. 44).

6. Route new belt through idler arm (Fig. 44).

7. Reinstall idler pulley and route belt onto other pulleys

(Fig. 45).

8. Retighten outer nut on spring eye bolt (Fig. 44). Note: Check spring length. The spring should measure

9.375″ ± .125″ (238 mm ±.3 mm) when installed. Adjust if it does not (Fig. 44).

9. Install belt covers over outside spindles.

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

pressure on spring loaded idler (Fig. 46).

6. Reinstall deck belt.

Page 39

m–4119

Figure 46

1. Clutch strap

2. Bolt

3. Clutch electrical wire

4. Belt

5. Idler

6. Clutch

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 14.

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. 48).

M-4118

Figure 47

1. Right-hand motion control lever (shown)

2. Neutral lockout position

4. If adjustment is needed, loosen the nut against the yoke (Fig. 48).

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. 48).

6. Tighten nut and jam nut.

7. Repeat on opposite side of unit.

3. Check where lever is relative to notch in console

(should be centered allowing lever to pivot outward to the neutral lock position) (Fig. 47).

Page 40

Warning

Engine must be running so motion control

4 3

2 7

adjustment can be performed. Contact with moving parts or hot surfaces may cause personal injury.

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

2. Slide seat forward, disconnect prop rod and tilt seat

fully forward.

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

4. Loosen locknut at ball joint on pump control rod (Fig. 48).

m–4118

Figure 48

1. Clevis pin in slot

2. Nut

3. Nut—left-hand thread

4. Bolt

5. Pump rod

6. Double nuts

7. Jam nut

8. Yoke

Adjusting Hydraulic Pump Neutral

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

Danger

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

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

1. This adjustment must be made with drive wheels

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

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

Note: The front nut of each rod has left-hand threads.

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. 48).

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, readjust if necessary.

9. Repeat on opposite side of unit. Tighten locknuts against ball joints.

Warning

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

• Remove jumper wire from wire harness

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

• Never operate this unit with jumper installed

and seat switch bypassed.

10.Shut off unit. Remove jumper wire from wire harness

connector and plug connector into seat switch.

11. Reinstall prop rod and lower seat.

Page 41

Adjusting 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. 49).

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

the spring and tighten the nut directly below the yoke (Fig. 49). Turn the nut until the correct measurement is obtained. Tighten the two nuts together and repeat on opposite side of unit.

4. Turn nuts clockwise to shorten spring length and turn

counterclockwise to lengthen the spring.

5. Engage parking brake, lever up.

Fuse: Main F1—20 amp, blade-type

Alternator F2—20 amp, blade-type

1. Raise the seat to gain access to fuse holder (Fig. 50).

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

(Fig. 50).

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. 49).

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. 49). Tighten jam nut at yoke.

1. Brake lever

2. Spring 2.75″ (70 mm)

3. Adjusting nuts

4. Collar on brake rod

Figure 49

5. 3/16″–1/4″ (5–7 mm)

6. Jam nut and yoke

7. Trunion

m–4120

m–3653

Figure 50

1. Main—30 amp 2. Alternator—25 amp

Battery

Warning

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

handling.

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

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.

Checking Electrolyte Level

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

be up to the lower part of the tube (Fig. 51). Do not allow the electrolyte to get below the plates (Fig. 51).

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

distilled water; refer to Adding Water to the Battery.

Page 42

1. Filler caps

2. Lower part of tube

Figure 51

3. Plates

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.

1262

Warning

Charging battery produces gasses that can explode and cause serious injury.

• Keep cigarettes, sparks and flames away from

battery.

• Make sure the ignition switch is off.

• Ventilate when charging or using battery in an

enclosed space.

Waste Disposal

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

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

2. Lift off the filler caps (Fig. 51).

3. Slowly pour distilled water into each battery cell until

the level is up to the lower part of the tube (Fig. 51).

Important Do not overfill the battery because

electrolyte (sulfuric acid) can cause severe corrosion 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. Check the electrolyte level; refer to Checking

Electrolyte Level, page 41.

2. Remove the filler caps from the battery and connect a

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

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 states have passed laws concerning the disposal of devices containing mercury. In all the remaining states it is advisable to follow similar procedures. The laws state that these sealed devices contain mercury and should not be placed in the garbage until the mercury is removed and reused, recycled or otherwise managed to insure that it

Page 43

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.

Caution

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

• Never attempt to open or repair the tilt

switch.

• Avoid contact with the mercury.

Replacing the Grass Deflector

Warning

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

Never operate the lawn mower unless you install a cover plate, a mulch plate, or a grass chute and catcher.

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

m-5037

Figure 52

6. Grass Deflector

7. Place behind deck edge before installing bolt

8. Hook end of spring

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

the deflector to the pivot brackets (Fig. 52). Remove damaged or worn grass deflector.

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

straight end of spring behind deck edge.

Note: Make sure the straight end of spring is installed behind deck edge before installing the bolt as shown in figure 52.

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

grass deflector (Fig. 52).

Important The grass deflector must be able to lower

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

Page 44

Wiring Diagram

Page 45

Cleaning and Storage

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.

F. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

refer to Fuel Tank, page 31.

H. Restart engine and run until it stops. Repeat, on

“CHOKE” until engine will not restart.

I. Dispose of fuel properly. Recycle as per local

codes.

Important You can wash the machine with mild

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

3. Service the air cleaner; refer to Air Cleaner, page 28.

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

Lubrication, page 32.

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

Oil, page 29.

6. Change the hydraulic filter; refer to Hydraulic System,

page 16.

7. Check the tire pressure; refer to Tire Pressure, page 35.

8. Charge the battery; refer to Battery, page 41.

9. Check the condition of the blades; refer to Cutting

Blades, page 26.

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

over 30 days. Prepare machine for storage as follows.

11. Add a petroleum based stabilizer/conditioner to fuel in

the tank. Follow mixing instructions from stabilizer manufacture. (1 oz. per gallon or 7.8ml per liter). Do

not use an alcohol based stabilizer (ethanol or methanol).

Note: Do not store stabilizer/conditioned gasoline over 90

days.

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

refer to Spark Plug, page 30. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

13.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 drive and deck belts.

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

replace any part that is damaged or defective.

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

available from your Authorized Service Dealer.

18.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.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times.

A. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

refer to Fuel Tank, page 31. C. Restart engine and run it until it stops. D. 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. E. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

Page 46

Troubleshooting

g,,

Problem Possible Causes Corrective Action

Starter does not crank

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

1. Blade control (PTO) is ENGAGED.

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

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

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

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

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

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

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

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

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

5. Spark plug wires are loose or disconnected.

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

1. Move blade control (PTO) to DISENGAGED.

5. Check electrical connections for good contact.

Dealer.

element.

5. Install wires on spark plug.

6. Install new, correctly gapped spark plugs.

Engine loses power.

Engine overheats.

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

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

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

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

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

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

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

6. Vent in fuel cap is closed. 6. Open vent in fuel cap.

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

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

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

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

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

8. Contact Authorized Service Dealer.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plugs.

8. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

Page 47

Problem Corrective ActionPossible Causes

Machine does not drive.

Abnormal vibration.

1. Traction belt is worn, loose or broken.

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

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

1. Engine mounting bolts are loose.

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

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

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

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

6. Engine mounting bolts are loose.

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

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

1. Contact Authorized Service Dealer.

Dealer.

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

4. Install new cutting blade(s).

6. Tighten engine mounting bolts.

7. Tighten the appropriate pulley.

Dealer.

Uneven cutting height.

Blades do not rotate.

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

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

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

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

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

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

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

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

1. Drive belt is worn, loose or

broken.

2. Drive belt is off pulley. 2. Install drive belt and check

3. Deck belt is worn, loose or

broken.

1. Install new drive belt.

adjusting shafts and belt guides for correct position.

3. Install new deck belt.

Page 48

LCE

The Toro Total Coverage Guarantee

A One-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly promise to repair any Toro Product used for commercial, institutional, or rental purposes if defective in materials or workmanship. The following time periods apply from the date of purchase:

Products

• All Products 1 year

• All Spindles 2 years parts & labor,

• Engines* on the following: 2 years

Out Front and MidMount Zero Radius Tractors ProLine Mid-Size Mowers Groundsmaster Riding Mowers ProLine Hand Held Gas Products

(AE and LE engines only) Backpack Blowers

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

This warranty applies to:

• Z-Master Zero Radius Tractors

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

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

engine manufacturer.

Warranty Period

third year parts only

Instructions for Obtaining Warranty Service

Should you feel your Toro Product contains a defect in materials or workmanship, contact the dealer who sold you the product or any Authorized Service Dealer or Master Service Dealer. The Yellow Pages of your telephone directory is a good reference source. The dealer will either arrange service at his/her dealership or recommend another Authorized Service Dealer who may be more convenient. You may need proof of purchase (copy of registration card, sales receipt, etc.) for warranty validation.

If for any reason you are dissatisfied with the Service Dealer’s analysis of the defect in materials or workmanship or if you need a referral to a Toro Service Dealer, please feel free to contact us at:

LCB Customer Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 888-577-7466

Owner Responsibilities

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

Items and Conditions Not Covered

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

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

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

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

• Pickup and delivery charges.

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

General Conditions

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

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending complet i o n o f r e p a irs under this warranty. Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

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

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their T oro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

Rev. 02/04/2000

Toro 74178 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual