Toro 74199 Operator's Manual

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Page 1

Form No. 3329–814 Rev A

Z148

Z Master with 44 SFS Side Discharge Mower

Model No. 74199—Serial No. 230000001 and 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.

Important This engine is not equipped with a spark

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

This spark ignition system complies with Canadian ICES-002.

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

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

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

Contents

Page

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

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

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

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

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

Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 13. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . .

Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . .

Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Drive Wheels 14. . . . . . . . . . . . . . . . .

Tire Pressure 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Seat Retaining Rod 14. . . . . . . . . . . .

Installing the Motion Control Levers 15. . . . . . . . .

Activating the Battery 16. . . . . . . . . . . . . . . . . . . . .

Checking the Hydraulic Fluid 16. . . . . . . . . . . . . . .

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

Check the Level of Mower 17. . . . . . . . . . . . . . . . .

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

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

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

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

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

Controls 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Parking Brake 18. . . . . . . . . . . . . . . .

Using the Blowout Baffles 19. . . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 19. . . . . . . . . . . .

Operating the Power Take Off (PTO) 20. . . . . . . . .

The Safety Interlock System 20. . . . . . . . . . . . . . . .

Testing the Safety Interlock System 20. . . . . . . . . .

Driving Forward or Backward 21. . . . . . . . . . . . . . .

Stopping the Machine 21. . . . . . . . . . . . . . . . . . . . .

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

Adjusting Anti-Scalp Rollers 22. . . . . . . . . . . . . . . .

Positioning the Seat 23. . . . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 23. . . . . . . . . . . . . . .

Using a Rollover Protection System (ROPS) 23. . .

Operating with Side Discharge 23. . . . . . . . . . . . . .

Transporting Machines 24. . . . . . . . . . . . . . . . . . . .

Loading Machines 24. . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 25. . . . . . . . . . . . . . . . . . . .

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

Recommended Maintenance Schedule 26. . . . . . . .

Servicing the Cutting Blades 27. . . . . . . . . . . . . . . .

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

Air Cleaner 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling System 31. . . . . . . . . . . . . . .

Spark Plug 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Replacing the Fuel Filter 32. . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 33. . . . . . . . . . . . . . . . . . .

Greasing the Bearings 33. . . . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 34. . . . . . . . . . . . . . . . .

Adjusting the Wheel Hub Slotted Nut 34. . . . . . . . .

Adjusting the Caster Pivot Bearing 34. . . . . . . . . . .

Servicing the Hydraulic System 35. . . . . . . . . . . . .

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

Setting the Hydraulic Pump Neutral 38. . . . . . . . . .

Adjusting the Tracking 39. . . . . . . . . . . . . . . . . . . .

Adjusting the Parking Brake 39. . . . . . . . . . . . . . . .

Servicing the Fuse 40. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 40. . . . . . . . . . . . . . . . . . . . . .

Adjusting the Mower Level 42. . . . . . . . . . . . . . . . .

Cleaning Under the Deck 43. . . . . . . . . . . . . . . . . . .

Adjusting the Push Arms 44. . . . . . . . . . . . . . . . . . .

Inspecting the Belts 44. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Deck Belt 44. . . . . . . . . . . . . . . . . . .

Replacing the Pump Drive Belt 45. . . . . . . . . . . . . .

Replacing the Grass Deflector 45. . . . . . . . . . . . . . .

Page

Page 3

Page

Waste Disposal 46. . . . . . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch 46. . . . . . . . . . . . . . . . . . . . . . .

Mercury Tilt Switch Disposal 46. . . . . . . . . . . . . . .

Wiring Diagram 47. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 48. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Introduction

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

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

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

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

This manual uses two other words to highlight information. Important calls attention to special mechanical information and Note: emphasizes general information worthy of special attention.

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 attachments made by other

manufacturers 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.

m–3648

Figure 1

1. Location o f the model and serial numbers

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

Model No.

Serial No.

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

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

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

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

Safe Operating Practices

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

Training

• Read the Operator ’s Manual and other training

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

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

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

Page 4

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

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

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

• 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.

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

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

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

• Never raise deck with the blades running.

• Never operate without the PTO shield, or other guards

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

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or

overspeed the engine.

• Stop on level ground, lower implements, disengage

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

• Stop equipment and inspect blades after striking

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

• Keep hands and feet away from the cutting units.

• Never carry passengers and keep pets and bystanders

away.

• Be alert, slow down and use caution when making

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

• Slow down and use caution when crossing roads and

sidewalks. Stop blades if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs.

• Use extreme care when loading or unloading the

machine into a trailer or truck.

• Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure vision.

Slope Operation

• Do not mow slopes greater than 15 degrees.

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

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

• Do not mow slopes when grass is wet. Slippery

conditions reduce traction and could cause sliding and loss of control.

• Do not make sudden turns or rapid speed changes.

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

drop–offs, ditches, steep banks or water.

• Reduce speed and use extreme caution on slopes.

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

etc. from the mowing area. Tall grass can hide obstacles.

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

change the operating angle, as rough terrain could overturn the machine.

• Avoid sudden starts when mowing uphill because the

mower may tip backwards.

• Be aware that loss of traction may occur going

downhill. Weight transfer to the front wheels may cause drive wheels to slip and cause loss of braking and steering.

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

tires lose traction, disengage the blades and proceed slowly off the slope.

Page 5

• Follow the manufacturer ’s recommendations for wheel

weights or counterweights to improve stability.

• Use extreme care with grass catchers or other

attachments. These can change the stability of the

machine and cause loss of control.

Using the Rollover Protection System (ROPS)

• A rollbar is available and its use is recommended for

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

• When operating a machine with ROPS always use the

seat belt.

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

the machine is driven or rolls into ponds or water.

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

doorways, electrical wires) before driving under any

objects and do not contact them.

Maintenance and storage

• Disengage drives, lower implement, set parking brake,

stop engine and remove key or disconnect spark plug

wire. Wait for all movement to stop before adjusting,

cleaning or repairing.

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

• Use only Toro-approved attachments. Warranty may

be voided if used with unapproved attachments.

• Clean grass and debris from cutting units, drives,

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

or fuel spillage.

• Let engine cool before storing and do not store near

flame.

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

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with

stored energy.

• Disconnect battery or remove spark plug wire before

making any repairs. Disconnect the negative terminal

first and the positive last. Reconnect positive first and

negative last.

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

wear gloves, and use caution when servicing them.

Only replace blades. Never straighten or weld them.

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine

running.

• Charge batteries in an open well ventilated area, away

from spark and flames. Unplug charger before

connecting or disconnecting from battery. Wear

protective clothing and use insulated tools.

Page 6

Page 7

Slope Chart

Page 8

Page 9

Safety and Instruction Decals

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

1-643401

1–653140

1–653147

1-633818

43-8480

1-523552

66-1340

Page 10

67-5360

93-1122

93-7818

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

Operator’s Manual

for instructions on

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

98-5954

103–0262

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

Manual.

Operator’s

distance from the battery.

98-3798

98-4387

1. Warning—wear hearing protection.

104-8569

65–2690

Page 11

1. Engine

99-3943

99–3924

103–2644

106-6571

Page 12

106-6586

103-1997

1. Contains lead; do not discard.

2. Recycle

104-4164

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

4. No sparks, flame, or smoking

5. Sulfuric acid can cause blindness or severe burns.

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

7. Maximum fill line

8. Minimum fill line

9. Instructions for activating the battery

Page 13

Gasoline and Oil

Warning

Recommended Gasoline

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

Important Never use methanol, gasoline containing

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

Danger

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

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

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

• Never fill the fuel tank inside an enclosed

trailer.

• Do not fill the fuel tank completely full. Add

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

• Never smoke when handling gasoline, and stay

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

• Store gasoline in an approved container and

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

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle

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

• When practical, remove gas–powered

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

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used,

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

• Do not operate without entire exhaust system in

place and in proper working condition.

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 the Engine Oil Level, page 29.

Page 14

Setup

Loose Parts

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

Description Qty. Use

Rear Wheels 2 Installing the drive wheels Retaining rod

Bolt, 5/16 x 1 inch Locknut, 5/16 inch

Control lever–right Control lever–left Bolt, 3/8 x 1 inch Spring washer, 3/8 inch

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

Installing the seat retaining rod

Installing the motion control levers

Read before operating machine

Installing the Drive Wheels

1. Uncrate mower.

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

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

to the outside of the traction unit.

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

95 ft-lb (128 NM).

Important Make sure that wheel nuts are torqued to

95 ft–lb (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

Installing the Seat Retaining Rod

1. Tilt seat up. Remove the locknut (5/16 inch) from bolt

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

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).

Page 15

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

mounting tab of the seat frame and secure with a bolt (5/16 x 1 inch) bolt and locknut 5/16 inch (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 inch

3. Bolt, 5/16 x 1 inch

Installing the Motion Control Levers

4 5 6

m–5596

Figure 4

1. Mounting plate

2. Bolt, 3/8 x 1 inch

3. Spring washer, 3/8 inch

4. Top hole

5. Middle hole

6. Bottom hole

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 outward to the neutral lock position and carefully bend them outward. Move them back to the drive position and check for clearance. Repeat if necessary.

FRONT

UNIT

There are two positions to install the control levers, high and low. Install levers in the top and middle holes for the high position. Install levers in the middle and bottom holes for the low position.

1. Remove the 4 bolts (3/8 x 1 inch) and 4 spring washers

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

2. Place the levers (with the mounting plate toward the

rear) on the outside of the control arm shaft and secure with 4 bolts (3/8 x 1 inch) and 4 spring washers (3/8 in.) (Fig. 4).

3. Position the levers 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 adjustment by sliding/tilting the lever(s) forward or backward until properly aligned (Fig. 4).

LEVERS IN

ALIGNMENT

Figure 5

Page 16

Activating the Battery

Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.

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.

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.

7. Charge the battery. Refer to Charging the Battery on

page 42.

8. Install the battery into the machine. Refer to Installing

the Battery on page 41.

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

1. Remove the battery from the machine. Refer to

Removing the Battery on page 41.

2. Clean the top of the battery with a paper towel. Note: Never fill the battery with electrolyte while the

battery is installed in the machine. Electrolyte could be spilled on other parts and cause corrosion.

3. Remove the vent caps from the battery (Fig. 55).

4. Slowly pour electrolyte into each battery cell until the

level is up to the upper line (Fig. 55) on the battery case.

Important Do not overfill the battery because

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

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

Add electrolyte, if necessary, until the electrolyte level is up to the upper line (Fig. 55) on the battery case.

6. Reinstall battery filler caps.

Checking the Hydraulic Fluid

Check the hydraulic fluid level before the engine is first started.

Refer to Checking the Hydraulic Fluid on page 35.

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.

1. Grease the fittings on the three spindle bearings.

Grease until it comes out lower seals (Fig. 7).

2 3

1. Filler caps

2. Upper line

Figure 6

3. Lower line

m–5004

M–4269

Figure 7

1. Spindles

Page 17

Check the Level of Mower

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

Refer to Adjusting the Mower Level section on page 42.

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 the Engine Oil Level, page 29.

Operation

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

Think Safety First

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

Danger

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

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

m–6478

Figure 8

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

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

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

3. Water

Caution

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

Wear hearing protection when operating this machine.

A rollbar is available and its use is recommended for areas where there are slopes, drop–offs or water.

To avoid loss of control and possibility of rollover:

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

• Do not mow slopes greater than 15 degrees.

• Reduce speed and use extreme caution on

slopes.

• Avoid sudden turns or rapid speed changes.

Figure 9

1. Warning—wear hearing protection.

Page 18

Controls

Become familiar with all the controls (Fig. 10) before you start the engine and operate the machine.

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 12

1. Shut-off valve

Operating the Parking Brake

m–6749

Figure 10

1. Ignition switch

2. Motion control lever

3. Parking brake lever

4. Throttle

5. Choke

6. Power take off (PTO)

7. Height-of-Cut lever

8. Fuel cap

9. Hourmeter

10. Fuel shut-off valve

Using the Hour Meter

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

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. 10) out to the

neutral lock position.

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

parking brake (Fig. 13). The parking brake lever should stay firmly in the engaged position.

Releasing the Parking Brake

1. Push forward and down on the parking brake lever to

release the parking brake (Fig. 13). The parking brake is disengaged and the lever rests against the brake stop.

m–4202

Figure 11

1. Hour meter

Switching the Fuel Tanks

The unit has two fuel tanks, one located on the left side and one on the right side. Each tank connects to the fuel shut off valve in the control panel. From there a common fuel line leads to the engine (Fig. 12).

m–4121

Figure 13

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

Page 19

Using the Blowout Baffles

Blowout baffles are used when in side discharge mode only.

7. After the engine starts, move the choke to off (Fig. 16).

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.

Important Do not use blowout baffles while in

recycling mode.

1. To install or remove blowout baffles, install or remove

bolts as shown in Figure 14.

M–4661

Figure 14

1. Bolts

2. Front of deck

3. Baffles

Starting and Stopping the

Figure 15

1. PTO—On

2. PTO—Off

m–4201

m–2719

Figure 16

1. Choke—On

2. Choke—Off

Engine

Starting the Engine

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

neutral locked position.

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

Brake, page 18.

3. Move the PTO (power take off) to the off position

(Fig. 15).

4. Move the choke control to on position before starting a

cold engine (Fig. 16).

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

5. Move the throttle control to the fast position before

starting a cold engine (Fig. 17).

6. Turn ignition key to start to energize starter. When

engine starts, release key (Fig. 18).

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.

M–4268

Figure 17

1. Fast

2. Slow

m–2720

Figure 18

1. Off

2. Run

3. Start

Stopping the Engine

1. Push the PTO to off (Fig. 17).

2. Move the throttle lever midway between the slow and

fast positions (Fig. 17).

3. Let the engine idle for 60 seconds (Fig. 18).

4. Turn the ignition key to off (Fig. 18).

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

someone accidentally starting the machine before transporting or storing machine.

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

transporting or storing machine.

Page 20

Important Make sure that the fuel shut off valve is

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

Caution

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

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

Operating the Power Take Off (PTO)

The Safety Interlock System

Caution

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

• You are sitting on the seat.

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

Engaging the PTO

1. While seated in the seat, release 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

the PTO (Fig. 19).

m–4201

Figure 19

1. PTO—Off 2. PTO—On

Disengaging the PTO

1. To disengage push the PTO switch to the off position

(Fig. 19).

• The parking brake is engaged.

• The power take off (PTO) is disengaged.

• 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 from the locked position with the parking brake engaged or if you rise from the seat when the PTO is on or engaged.

Testing the Safety Interlock System

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

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

the PTO to on. Try starting the engine; the engine should not crank.

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

the PTO to on. Move either motion control lever (out of neutral locked position). Try starting the engine; the engine should not crank. Repeat for other control lever.

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

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

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

PTO switch to off, and move the motion control levers to neutral lock position. Now start the engine. While

Page 21

the engine is running, center either motion control and move (forward or reverse); the engine should stop. Repeat for other motion control.

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

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

Driving Forward or Backward

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

Caution

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

• Use caution when making turns.

• Slow the machine down before making sharp

turns.

Driving 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. 20).

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. 20).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 20).

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 20

1. Motion control lever—neutral lock position

2. Center unlock position

3. Forward

4. Backward

Driving Backward

1. Move levers to the center, unlocked position.

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

rearward (Fig. 20).

To go straight, apply equal pressure to both motion control levers (Fig. 20).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 20).

To stop push the motion control levers to neutral.

Stopping the Machine

To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. 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 key and set the parking brake when leaving the machine unattended, even if just for a few minutes.

Adjusting the Height-of-Cut

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

Page 22

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

(also the 4-1/2 inch (114 mm) cutting height position) (Fig. 21).

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

height-of-cut bracket (Fig. 21).

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

the height-of-cut desired, and insert clevis pin (Fig. 21).

4. Secure clevis pin with hairpin cotter (Fig. 21).

m–4122

Figure 21

1. Height-of-cut lever

2. Clevis pin

3. Hairpin cotter

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

m–4167

Figure 22

1. Gage wheel

2. Stud

3. Washer

4. Nut

5. Wheel nut and washer. Do not remove.

Adjusting the Center Rollers

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

ignition key to off. Move controllers to neutral locked position and apply parking brake.

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

(Fig. 23).

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

corresponding height-of-cut desired (Fig. 23).

Adjusting Anti-Scalp Rollers

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

Adjusting the Outside 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. Remove the key.

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

while holding stud with wrench (Fig. 22).

Note: Do not remove the wheel nut and washer (Fig. 22).

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

corresponding height-of-cut desired (Fig. 22).

4. Reinstall the flange nut and spring disk. Torque to

40–45 ft-lb (54.2–61.0 Nm) (Fig. 22).

5. Repeat adjustment on other gage wheels.

Note: Do not adjust rollers to support the deck.

4. Reinstall the bolt, center rollers and nut (Fig. 23).

Figure 23

1. Center rollers and spacer

2. Nut

3. Bolt

m–4124

Page 23

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. 24).

Note: The machine will not drive unless by-pass valves are turned in.

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

to lock in position.

m–6750

Figure 24

1. Adjustment lever

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

m–6279

Figure 25

1. By-pass valve

Using a Rollover Protection System (ROPS)

A ROPS is available and its use is recommended for areas where there are slopes, drop–offs or water. Contact an Authorized Service Dealer for information on obtaining ROPS for your machine.

Important When operating a machine with ROPS

always use the seat belt.

Operating with Side Discharge

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

To Push the Machine

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

ignition key to off. Move levers to neutral locked position and apply parking brake.

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. 25).

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.

3. Disengage parking brake before pushing.

Changing to Machine Operation

1. Rotate the by-pass valves clockwise 1 turn to operate

machine (Fig. 25).

Note: Do not over tighten the by–pass valves.

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).

Page 24

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 the safety instructions. 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

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

Do not drive machine on a public street or roadway.

Warning

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

• Use extreme caution when operating a unit on a

ramp.

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

individual ramps for each side of the unit.

• If individual ramps must be used, use enough

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

• Do not exceed a 15 degree angle between ramp

and ground or between ramp and trailer or truck.

• Avoid sudden acceleration while driving unit up

a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing unit

down a ramp to avoid tipping backward.

Loading Machines

Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Fig. 26). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

The ramp should be long enough so that the angles do not exceed 15 degrees (Fig. 26). A steeper angle may cause mower deck components to get caught as the unit moves from ramp to trailer or truck. Steeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

Important Do Not attempt to turn the unit while on

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

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

m–6841

1. Trailer

2. Full width ramp

3. Not greater than 15 degrees

Figure 26

4. Full width ramp—side view

Page 25

Tips for Mowing Grass

Fast Throttle Setting

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

Cutting a Lawn for the First Time

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

Cut 1/3 of the Grass Blade

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

Mowing Direction

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

Long Grass

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

When Stopping

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

Keep the Underside of the Mower Clean

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

Blade Maintenance

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

Mow at Correct Intervals

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

Cutting Speed

To improve cut quality, use a slower ground speed.

Avoid Cutting Too Low

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

Page 26

Maintenance

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

Recommended Maintenance Schedule

Maintenance Service

Interval

Each Use

Every 5 Hours • Check the cutting blades.

Every 25 Hours

Every 100 Hours

Every 200 Hours

Maintenance Procedure

• Check the engine oil level.

• Check the safety system.

• Clean the cooling system.

• Clean the mower housing.

• Check the air cleaner.

• Grease all lubrication points.

• Oil the linkage bushings.

• Check the belts for wear/cracks.

• Check the battery electrolyte.

• Check the tire pressure.

• Change the engine oil.

• Inspect the paper element of the heavy duty air cleaner.

• Change the oil filter.

• Replace the fuel filter.

• Check the spark plug(s).

• Replace the paper element of the heavy duty air cleaner.

Every 600 Hours or at

Storage

Before Storage

More often in dusty, dirty conditions

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

• Replace safety air cleaner

• Perform all maintenance procedures listed above before storage.

• Drain the fuel tank.

• Charge the battery and disconnect the battery cables.

• Paint any chipped surfaces.

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.

Page 27

Servicing the Cutting Blades

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

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

Danger

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

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Figure 27

1. Cutting edge

2. Curved area

3. Wear/slot forming

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 28). Measure from a level surface to the cutting edge of the blades (Fig. 29). Note this dimension.

Front

m–151

Before Inspecting or Servicing the Blades

Disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Inspecting the Blades

1. Inspect the cutting edges (Fig 27). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 28.

2. Inspect the blades, especially the curved area (Fig. 27).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 27), immediately install a new blade.

m–1078

Figure 28

MEASURE FROM CUT-

TING EDGE TO A LEV-

EL SURFACE

m–2539

Figure 29

2. Rotate the opposite ends of the blades forward.

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

blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this

Page 28

dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 28.

Sharpening the Blades

Warning

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

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

Removing the Blades

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.

Warning

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

with a rag.

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

Wear proper eye protection when sharpening blade.

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

the blade (Fig. 31). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 31

1. Sharpen a t original angle

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

balancer (Fig. 32). 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. 30). Repeat this procedure until the blade is balanced.

Hold the blade end using a rag or thickly-padded glove. Remove the blade bolt, flat washer, split lockwasher and blade from the spindle shaft (Fig. 30).

m–4318

Figure 30

1. Sail area of blade

2. Blade

3. Flat washer

4. Blade bolt

5. Split lockwasher

m–1855

Figure 32

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 30).

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

Important Make sure blade is torqued to 85–110 ft-lb

(115–150 Nm).

Page 29

Engine Oil

Change the oil after every 100 operating hours. Oil Type: Detergent oil (API service SG, SH, SJ, or

higher)

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

not thread it onto the tube. Pull the dipstick out and look at the metal end (Fig. 34). If the oil level is low, slowly pour only enough oil into the filler tube to raise the level to, but not over, the “F” mark on the dipstick.

Crankcase Capacity: w/filter, 2.1 qt. (2 l) Viscosity: See the table below.

USE THESE SAE VISCOSITY OILS

10W–30

5W–20, 5W–30

–20 0 20

–30°–20 –10

40 60

01020

80 100

30 40

Checking the Oil Level

1. Park the machine on a level surface, disengage the

PTO, stop the engine, and remove the key.

2. Clean around the oil dipstick (Fig. 33) so that dirt

cannot fall into the filler hole and damage the engine.

m–6726

Figure 34

1. Oil dipstick 2. Metal end

Important Do not overfill the crankcase with oil

because the engine may be damaged.

Changing and Draining the Oil

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

warms the oil so that it drains better.

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

lower than the opposite side to ensure that the oil drains completely. Then disengage the PTO, set the parking brake, stop the engine, and remove the key.

m–6723

Figure 33

1. Oil fill/dipstick 2. Air cleaner

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

(Fig. 33).

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

cap (Fig. 35).

m–6722

Figure 35

1. Oil drain cap 2. Oil filter

4. When the oil has drained completely, install the drain

cap.

Page 30

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

5. Clean around the oil reservoir and unscrew the cap

(Fig. 35).

6. Slowly pour approximately 80% of the specified

amount of oil, page 29, into the filler tube (Fig. 33). Check the oil level; refer to Checking the Oil Level, page 29. Slowly add additional oil to bring the level to the “F” mark on the dipstick.

Air Cleaner

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

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

conditions are extremely dusty or sandy.

Removing the Filters

Changing the Oil Filter

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

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

1. Drain the oil from the engine; refer to Changing and

Draining the Oil, page 29.

2. Remove the old filter and wipe the filter adapter

(Fig. 36) gasket surface.

m–1256

Figure 36

1. Oil filter

2. Gasket

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

the replacement filter (Fig. 36).

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

Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 2/3 to 1 turn (Fig. 36).

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

refer to Changing and Draining the Oil, page 29.

3. Adapter

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

brake, and turn the ignition key to off. Remove the key.

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

cleaner cover off of the air cleaner body (Fig. 37).

m–6724

Figure 37

1. Latches

2. Air cleaner cover

3. Air filter body

4. Primary filter

5. Safety filter

3. Clean the inside of the air cleaner cover with

compressed air.

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

body (Fig. 37). Avoid knocking the filter into the side of the air cleaner.

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

Important Never attempt to clean the safety filter. If

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

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

Page 31

Servicing the Primary Filter

Removing the Spark Plug(s)

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

the filter. Do not clean the primary filter.

Servicing the Safety Filter

Replace it after 600 operating hours.

Important Never attempt to clean the safety filter. If

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

Installing the Filters

Important To prevent engine damage, always operate

the engine with both air filters and cover installed.

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

damage. Do not use a damaged filter.

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

into the filter body (Fig. 37).

3. Carefully slide the primary filter over the safety filter

(Fig. 37). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

Important Do not press on the soft inside area of the

filter.

4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 37).

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 38). 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.

m–5141

Figure 38

1. Spark plug wire 2. Spark plug

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 39). 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.

Cleaning the Cooling System

Clean the air intake screen before each use. Remove any buildup of grass, dirt, or other debris from the engine air intake.

Spark Plug

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

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

Figure 39

1. Center electrode insulator

2. Side electrode

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.

3. Air gap (not to scale)

0.030 in.

(0.76 mm)

m–3215

Page 32

2. Check the gap between the center and side electrodes

(Fig. 39). Bend the side electrode (Fig. 39) if the gap is not correct.

Installing the Spark Plug(s)

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

set correctly.

2. Tighten the spark plug(s) to 30 ft.-lb. (41 N⋅m).

3. Push the wire(s) onto the spark plug(s) (Fig. 38).

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.

5. Open the fuel shut-off valve. Allow gasoline to drain

into a gas can or drain pan.

m–6723

1. Fuel filter

2. Hose clamp

Figure 40

3. Fuel line

• Drain gasoline from the fuel tank when the

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

• Never smoke when draining gasoline, and stay

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

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

fuel tank drains completely. Then disengage the PTO, set the parking brake, stop the engine, and remove the key.

2. Close the fuel shut-off valve located under the front of

the fuel tank.

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

the fuel line away from the fuel filter (Fig. 40).

4. Pull the fuel line off of the fuel filter (Fig. 40).

Note: Now is the best time to install a new fuel filter

because the fuel tank is empty.

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

clamp close to the fuel filter to secure the fuel line (Fig. 40).

Replacing the Fuel Filter

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

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

1. Disengage the PTO, set the parking brake, stop the

engine, and remove the key.

2. Close the fuel shut-off valve located under the front of

the fuel tank.

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

them away from the filter (Fig. 40).

4. Remove the filter from the fuel lines.

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

the filter (Fig. 40).

6. Open the fuel shut-off valve.

Page 33

Greasing and Lubrication

Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 41). 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. Move levers to neutral locked position and apply parking brake. 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.

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 41).

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

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

bearing.

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

cap.

Greasing the Bearings

The cutting unit must be lubricated regularly. Refer to the Recommended Maintenance Schedule on page 26. 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. 42).

3. Grease the idler pulley pivot (Fig. 42).

4. Grease the fittings on the push arms (Fig. 42).

Figure 41

Greasing the Front Caster Pivots

Lubricate the front caster pivots once a year.

1. Remove the dust cap and adjust the caster pivots. Keep dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing, page 34.

M–4269

Figure 42

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.

Page 34

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 43). Check the tires when they are cold to get the most accurate pressure reading.

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

m–1872

Figure 43

1. Valve stem

Adjusting the Wheel Hub Slotted Nut

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

(170 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-lb (170 Nm) (Fig. 44).

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

edge of hole. Two threads or less should be showing (Fig. 44).

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

install washer between hub and nut (Fig. 44).

6. Torque the slotted nut to 125 ft-lb (170 Nm) (Fig. 44).

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

hole in the shaft (Fig. 44).

m–4638

Figure 44

1. Slotted n u t

2. Two threads or less showing

3. Hole in threaded rod

4. Washer (if needed)

Adjusting the Caster Pivot Bearing

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

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

2. Remove dust cap from caster and tighten lock nut (Fig. 45).

3. Tighten until spring washers are flat and then back off a 1/4 turn to properly set the pre–load on the bearings (Fig. 45).

4. Grease caster pivot. Refer to Greasing and Lubrication on page 33.

Important Make sure spring washers are installed

correctly as shown in figure 45.

8. Replace cotter pin.

1. Spring washers

2. Lock nut

M–4640

Figure 45

3. Dust cap

Page 35

Servicing the Hydraulic System

Check the hydraulic fluid level before engine is first started.

Check the hydraulic fluid level after first 8 operating hours.

Check the hydraulic fluid level after every 25 operating hours.

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

Important Use oil specified or equivalent. Other

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

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

Checking the Hydraulic Fluid, Cold

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

brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 46).

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

there is fluid in the reservoir. (Fig. 46).

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

5. Install cap on filler neck.

Checking the Hydraulic Fluid, Hot

Figure 46

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

m–5615

Note: Check the hydraulic fluid after using the machine for the first time. This allows any air to be purged from the system.

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

2. Clean area around filler neck of hydraulic tank (Fig. 46).

3. Remove cap from filler neck.

4. Recheck the fluid level while the fluid is warm. If

required, add fluid to the reservoir until it reaches the hot level of the baffle.

Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is warm (Fig. 46).

5. Install cap on filler neck.

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. 47).

Page 36

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.

m–4117

Figure 47

1. Hydraulic filter

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

the replacement filter (Fig. 48).

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. 48).

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.

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.

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.

m–1256

Figure 48

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 inch (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 36.

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

• 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.

Adjusting the 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 Installing the Motion Control Levers, page 15.

Page 37

1. Stop the engine, remove ignition key and tilt seat

forward.

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

3. Move lever to the neutral position but not locked

(Fig. 49).

8 1

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

shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig. 50).

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

console (Fig. 49). It should be centered allowing lever to pivot outward to the neutral lock position.

m–6282

Figure 49

1. Neutral locked position

2. Control lever

3. Neutral potion

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

against the yoke (Fig. 50).

m–4118

1. Clevis pin in slot

2. Nut

3. Nut—Left hand thread

4. Adjustment bolt

5. Pump rod

Figure 50

6. Double nuts

7. Jam nut

8. Yoke

9. Ball joint

4 3

2 7

7. Apply slight rearward pressure on the motion control

lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 49).

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

8. Tighten the nut and jam nut (Fig. 50).

9. Repeat on the opposite side of unit.

Page 38

Setting the 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.

4. Open throttle to fast. Make sure wheel remains

stopped or slightly creeps in reverse, adjust if necessary.

Warning

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

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

This adjustment must be made with drive wheels turning.

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

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

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

Setting the Left–hand Hydraulic Pump Neutral

1. Start the engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 19.

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

2. Adjust pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 51).

3. Move motion control lever forward and reverse, then back to neutral. Wheel must stop turning or slightly creep in reverse.

m–6283

Figure 51

1. Tracking knob

2. Pump rod

3. Adjustment bolt

Setting the Right–hand Hydraulic Pump Neutral

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

rod (Fig. 50).

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

parking brake. Refer to Starting and Stopping the Engine, page 19.

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

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

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

in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 50).

4. Move motion control lever forward and reverse, then

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

5. Open throttle to fast. Make sure wheel remains

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

6. Tighten the nuts at the ball joints (Fig. 50).

Page 39

Warning

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

• Remove jumper wire from wire harness

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

• Never operate this unit with jumper installed

and seat switch bypassed.

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

8. Remove jumper wire from wire harness connector and

plug connector into seat switch.

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

Adjusting the Tracking

1. Pump rod

2. Turn this way to track left

m–6280

Figure 52

3. Tracking knob

4. Turn this way to track right

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

Important Adjust the handle neutral and hydraulic

pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral on page 36 and Adjusting the Hydraulic Pump Neutral on page 38.

1. Push both control levers forward the same distance.

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

the machine and set the parking brake.

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

from the normal operating position.

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

the rightside of the machine. Refer to figure 52.

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

the leftside of the machine. Refer to figure 52.

6. Repeat adjustment until the tracking is correct.

Adjusting the Parking Brake

Check parking brake for proper adjustment.

1. Disengage brake lever (lever down).

2. Measure the length of the spring. Measurement should

be 2-3/4 inch (70 mm) between washers (Fig. 53).

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

the spring and tighten the nut directly below the yoke (Fig. 53). 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.

6. Measure the distance between the trunnion roller and

the collar on brake rod. Measurement should be 3/16 –1/4 inch (5–7 mm) (Fig. 53).

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

below the yoke. Turn the bottom adjusting nuts until the correct measurement is obtained (Fig. 53). Tighten jam nut at yoke

Page 40

Servicing the Battery

M–4120

Figure 53

1. Brake lever

2. Spring 2–3/4 inch (70 mm)

3. Adjusting nuts

4. Collar on brake rod

5. 3/16 –1/4 inch (5–7 mm)

6. Jam nut and yoke

7. Trunion

Servicing the Fuse

Service Interval/Specification

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

Fuse: Main F1—20 amp, blade-type

Alternator F2—20 amp, blade-type

Warning

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

handling.

Checking Electrolyte Level

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

battery.

2. Look at the side of the battery. The electrolyte must be up to the upper line (Fig. 55). Do not allow the electrolyte to get below the lower line (Fig. 55).

3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 41.

1 2 3

1. Raise the seat to gain access to fuse holder (Fig. 54).

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

(Fig. 54).

m–3653

Figure 54

1. Main—20 amp 2. Alternator—20 amp

m–5004

Figure 55

1. Filler caps

2. Upper line

3. Lower line

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.

Page 41

Installing the Battery

6 7

1. Position battery in tray with terminal posts toward the

engine (Fig. 56).

Removing the Battery

Warning

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

(+) battery terminal.

3. Then install negative battery cable and ground wire to

the negative (–) battery terminal.

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

(1/4 inch), and 2 locknuts (1/4 inch) (Fig. 56).

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

battery post.

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

washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 56).

9 5

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

• When removing or installing the battery, do not

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

• Do not allow metal tools to short between the

battery terminals and metal parts of the machine.

Warning

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

• Always Disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always Reconnect the positive (red) battery

cable before reconnecting the negative (black) cable.

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

5. Ground wire

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

Figure 56

7. Washer, 1/4 inch

8. Locknut, 1/4 inch

9. Battery clamp

10. J-bolts

11. Wing nut, 1/4 inch

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

brake, and turn the ignition key to off. Remove the key.

m–5598

2. Tilt seat up.

3. First disconnect the negative battery cable and ground

wire from the negative (–) battery terminal (Fig. 56).

4. Slide the red terminal boot off the positive (red)

battery terminal. Then remove positive (red) battery cable (Fig. 56).

5. Remove both wing nuts (1/4 inch) securing the battery

clamp (Fig. 56).

6. Remove the battery.

Adding Water to the Battery

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

1. Remove the battery from the machine.

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

Page 42

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

3. Remove the vent caps from the battery (Fig. 55).

4. Slowly pour distilled water into each battery cell until

the level is up to the upper line (Fig. 55) on the battery case.

Important Do not overfill the battery because

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

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

Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 55) on the battery case.

6. Reinstall battery vent caps.

Charging the Battery

3 1

Figure 57

1. Positive Battery Post

2. Negative Battery Post

5. Install the battery in the machine and connect the battery cables; refer to Installing the Battery on page 41.

3. Red (+) Charger Lead

4. Black (–) Charger Lead

m–4970

Warning

Charging the battery produces gasses that can explode.

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

Important Always keep the battery fully charged

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

1. Remove the battery from the chassis; refer to

Removing the Battery, page 41.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 40.

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

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

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

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 57).

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

Adjusting the Mower Level

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. 58). 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. 59).

5. Place two 1-1/4 inch (35 mm) thick blocks under rear left and right lower edge of mower. Place one 1-3/8 inch (44 mm) block under front center lower edge of mower. Not under anti-scalp roller brackets. Lower mower to the 1-1/2 inch (38 mm) height-of-cut position (Fig. 58).

Page 43

m–4122

Figure 58

1. Transport position 2. 1-1/2 inch (38 mm) height-of-cut

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

Repeat for opposite side. (Fig. 59).

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. 59).

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 inch (38 mm) position. Press down on the rear deck support arm to firmly return the deck lift handle to the 1-1/2 inch (38 mm) position (Fig. 59).

Note: Do not push on deck lift handle.

m–4116

Figure 59

1. Bottom chain bolt

2. T op chain bolt

3. Front swivel

4. 10-1/4 inch (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 (76 mm) height of cut and measure actual height from blade tips to ground. Height of cut for the front blade tips should be 3 inch ± 1/8 inch (76 mm ± 3 mm). Height of cut for rear blade tips should be 3–1/4 inch ± 1/8 inch (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.

13.Install anti-scalp rollers for proper height-of-cut and tighten securely. See Adjusting Anti Scalp Rollers on page 22.

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. 59). 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.

14.Raise deck lift lever to the transport position (Fig. 58).

15.Adjust compression springs by turning the front spring

nuts so the distance between the two large washers is 10-1/4 inch (260 mm). Then tighten jam nut (Fig. 59).

Note: Make sure all hardware is tight.

Cleaning Under the 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.

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

stands.

Page 44

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

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

2. Remove belt covers over outside spindles.

3. Loosen outer nut on spring eye bolt (Fig. 61).

Adjusting the Push Arms

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

joint counterclockwise, one turn at a time. (Fig. 60).

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

should have a nominal length of 15-5/16 inch (389mm) (Fig. 60).

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

1. Push arm

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

Figure 60

m–6273

3. Jam nut

4. Ball joint

M–4197

Figure 61

Top View

1. Outer nut

2. Idler pulley

3. Idler arm

4. Spring eye bolt

5. Spring

6. 9–3/8 inch ± 1/8 inch (238±.3 mm)

7. Deck belt

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

(Fig. 62).

Note: Do not remove spring.

Caution

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

Inspecting the Belts

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.

Do not remove spring from spring eye bolt.

5. Remove spring loaded idler pulley (Fig. 61).

6. Route new belt through idler arm (Fig. 61).

7. Reinstall idler pulley and route belt onto other pulleys

(Fig. 62).

8. Retighten outer nut on spring eye bolt (Fig. 61). Note: Check spring length. The spring should measure

9–3/8 inch ± 1/8 inch (238 mm ± 3 mm) when installed. Adjust if it does not (Fig. 61).

9. Install belt covers over outside spindles.

Page 45

M–4269

Figure 62

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 44.

2. Remove bolt from clutch strap and unplug clutch

electrical wire (Fig. 63).

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

from the engine and hydro pump pulleys (Fig. 63).

4. Install new belt around engine and hydro pump pulleys

(Fig. 63).

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

pressure on spring loaded idler (Fig. 63).

6. Reinstall deck belt.

m–4119

Figure 63

1. Clutch strap

2. Bolt

3. Clutch electrical wire

4. Belt

5. Idler

6. Clutch

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. Remove the locknut, bolt, spring and spacer holding

the deflector to the pivot brackets (Fig. 64). 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 64.

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

grass deflector (Fig. 64).

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 46

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

Figure 64

6. Grass Deflector

7. Place behind deck edge

8. Hook end of spring

m–5037

before installing bolt

Waste Disposal

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

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 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.

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.

Page 47

Wiring Diagram

TAN

RED

PINK

WIRE COLOR CODES

BLUE

BROWN

BLACK

IA YB

SW1

(IGNITION)

WHITE

VIOLET

VIO

GREY

GREEN

YELLOW

DK.GN

ORANGE

DARK GREEN/WHITE DARK GREEN

DK.GN/W

DARK BLUE

PINK/BLACK

DK.BU

PK/BK

LIGHT BLUE

ORANGE/BLACK

LT.BU

OR/BK

VIO

OR R YOR

LIGHT GREEN BLACK/RED

LT.GN BK/R

SPARK PLUG

20A

IGNITION

MODULE

MAG

HOUR

METER

GND

–+

BATTERY

235

OR/BK

DK.GN/W

OR/BK

STARTER

DK.GN

m–6725

(KILL RELAY)

FUEL

SOLINIOD

REG

VIO

–

FUEL

DK.GN

DK.BU

OIL

DK.BU

SWITCH CLOSES

WITH PRESSURE

SWITCH

KEY SWITCH PN 88–9830

OFF NO CONNECTION

ON B I A AND X Y

START B I S

KOHLER AIR–COOLED

KEY SW

TERMINAL VIEW FROM

BACK OF SWITCH

SW2

(PTO)

SHOWN IN

OFF POSITION

PK/BK

DK.GN

SW6

SW3

(BRAKE)

(SEAT SW)

SHOWN WITH

OPERATOR

IN SEAT

P1–A

DELAY MODULE

100–6186

LT.BU

DISENGAGED

SHOWN WITH

PARK BRAKE

P1–C P2–C

LT.BU

PTO

CLUTCH

P1–B

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

SW4

(NEUTRAL)

LT.GN

(START RELAY)

SHOWN WITH

LEVER IN

NEUTRAL

POSITION

SW5

(NEUTRAL)

DK.GN

GND

Page 48

Cleaning and Storage

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

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

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

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

Important You can wash the machine with mild

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

3. Service the air cleaner; refer to Air Cleaner, page 30.

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

Lubrication, page 33.

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

Oil, page 29.

6. Change the hydraulic filter; refer to Servicing the

Hydraulic System, page 35.

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

Pressure, page 34.

8. Charge the battery; refer to Servicing the Battery

page 40.

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

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

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

the Cutting Blades on page 27.

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

over 30 days. Prepare machine for storage as follows.

A. Add a petroleum based stabilizer/conditioner to

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

based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline and used at all times.

B. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

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

until it will not start. Operate primer, if equipped

on machine, several times to ensure fuel remains in

primer system. F. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

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

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

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

replace any part that is damaged or defective.

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

available from your Authorized Service Dealer.

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

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

Page 49

Troubleshooting

Problem Possible Causes Corrective Action

Starter does not crank

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

1. Blade control (PTO) is engaged.

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

3. Operator is not seated.

4. Battery is dead.

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.

2. Fuel valve turned off.

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 disengage.

3. Sit on the seat.

4. Charge the battery.

5. Check electrical connections for good contact.

Dealer.

1. Fill fuel tank with gasoline.

2. Open fuel valve.

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 50

Problem Corrective ActionPossible Causes

Abnormal vibration.

Machine does not drive.

Abnormal vibration.

1. Engine mounting bolts are loose.

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

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

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.

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

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

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

1. Contact Authorized Service Dealer.

Dealer.

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

3. Contact Authorized Service Dealer.

4. Install new cutting blade(s).

Uneven cutting height.

6. Engine mounting bolts are loose.

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

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

9. Blade spindle bent. 9. Contact Authorized Service

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

4. Gage wheel not set correctly.

5. Underside of mower is dirty.

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

7. Blade spindle bent. 7. Contact Authorized Service

6. Tighten engine mounting bolts.

7. Tighten the appropriate pulley.

Dealer.

and front-to-rear.

4. Adjust gage wheel height.

5. Clean the underside of the mower.

Dealer.

Page 51

Problem Corrective ActionPossible Causes

Blades do not rotate.

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 52

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

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

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

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

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

ProLine Mid-Size Mowers Mid-Mount Z’s

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

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

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

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

engine manufacturer.



Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

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

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

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

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

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

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

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

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

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

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

• Pickup and delivery charges.

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

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

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

Some states d o n o t a l l o w exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

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

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

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

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

Part No. 374-0037 Rev. C