Toro 74211 Operator's Manual

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Page 1

FORM NO. 3321–672 Rev A

Z–Master

250

Series



Liquid Cooled

Z252L

with 52” SFS Side

Discharge Mower

Model No. 74211–990001 & UP

Operator’s Manual

IMPORTANT: Read this manual carefully. It contains information about your

safety and the safety of others. Also become familiar with the controls and their proper use before you operate the product.

Page 2

Introduction

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

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

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

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

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

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

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

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

1. Model

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

Model No:

Serial No.

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

and Serial Number Plate

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

The engine exhaust from this product

contains chemicals known to the State of

California to cause cancer, birth defects,

or other reproductive harm.

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

The Toro Company – 1999

Page 3

Contents

Page

Safety 2.

Gasoline and Oil 12

Assembly 14

Operation 22

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Safe Operating Practices 2 Slope Chart 6 Safety and Instruction Decals 8

Recommended Gasoline12. . . . . . . . . . . . . .

Stabilizer/Conditioner 13 Filling the Fuel Tank 13 Check Engine Oil Level 13

Loose Parts 14 Install Drive Wheels 15 Tire Pressure 15 Install Seat Retaining Rod 15 Install Motion Control Levers 16 Activate the Battery 17 Install Battery 18 Check Engine Oil Level 19 Check Side Dischar Check the Leveling of Mower Deck 19

Cooling System19. . . . . . . . . . . . . . . . . . . . .

Hydraulic System 21

Think Safety First 22 Controls 22 Parking Brake 22 Starting and Stopping

the Engine 23 Operating the Power Take Off (PTO) 24 The Safety Interlock System 25 Driving Forward or Backward 26 Stopping the Machine 26 Instruments 27 Fuel Tanks 27

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ge Chute19. . . . . . . . . . .

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Adjusting Height-of-Cut 27 Adjusting Anti-Scalp Rollers 28 Positioning the Seat 29 .Pushing the Machine by Hand 29 Tips for Mowing Grass 30

Maintenance 31

Service Interval Chart 31

Cutting Blades32. . . . . . . . . . . . . . . . . . . . . .

Air Cleaner 35 Engine Oil 36

Cooling System38. . . . . . . . . . . . . . . . . . . . .

Spark Plug 42 Greasing and Lubrication 43 Tire Pressure 44 Fuel Filter 44 Fuel Tank 45 Hydraulic System 46 Adjusting Motion Controls Replacing the Pump Drive Belt 50 Adjustment Parking Brake 51 Fuse 51 Battery 52 Mower Leveling 53

Greasing the Bearings54. . . . . . . . . . . . . . . .

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

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

Replacing the PTO Drive Belt 55 Replacing the Alternator Belt 57 Replacing the Grass Deflector 57 Wiring Diagram 58 Wiring Diagram 59

Cleaning and Storage 60 Troubleshooting 61 Warranty 62

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Page 4

Contents

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

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Page 5

Safety

This machine meets or exceeds CPSC blade safety requirements for rotary mowers and the B71.4 1990 specifications of the American National Standards Institute, in effect at time of production.

Note: The addition of certain attachments

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

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

Safe

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

Operating Practices

POTENTIAL HAZARD

• Engine exhaust contains carbon monoxide,

which is an odorless, deadly poison.

WHAT CAN HAPPEN

• Carbon monoxide can kill you and is also

known to the State of California to cause birth defects.

HOW TO AV

OID THE HAZARD

• Do not run engine indoors or in an enclosed

area.

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

Note: This engine is not equipped with a

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

Page 6

Safety

General Operation

1. Read, understand, and follow all instructions in

the operator’s manual and on the machine before starting.

2. Allow only responsible adults who are familiar

with the instructions to operate the machine.

3. Clear the area of objects such as rocks, toys,

wire, etc., which could be picked up and thrown by the blade.

4. Be sure the area is clear of other people before

mowing. Stop the machine if anyone enters the area.

5. Never carry passengers.

6. Do not mow in reverse unless absolutely

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

7. Be aware of the mower discharge direction and

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

16. Use extra care when loading or unloading the

machine onto a trailer or truck.

17. Do not touch equipment or attachment parts

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

18. Before operating a machine with ROPS (roll

over protection) be certain the seat belts are attached.

8. Slow down before turning. Sharp turns on any

terrain may cause loss of control.

9. Never leave a running machine unattended.

Always turn off blades, set parking brake, stop engine, and remove key before dismounting.

10. Turn off blades when not mowing.

11. Keep hands, feet, hair and loose clothing away

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

12. Stop the engine before removing the grass

catcher or unclogging the chute.

13. Mow only in daylight or good artificial light.

14. Do not operate the machine while under the

influence of alcohol or drugs.

15. Watch for traffic when operating near or crossing

roadways.

Page 7

Safety

Slope Operation

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

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

across.

• Mow downhill only on slopes above 10°, never

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

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

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

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

while on the slope.

• Follow the manufacturer’s recommendations for

wheel weights or counterweights to improve stability.

• Use extra care with grass catchers or other

attachments. These can change the stability of the machine.

• Keep all movement on slopes slow and gradual.

Do not make sudden changes in speed or direction.

all grass can hide obstacles.

• Check carefully for overhead clearances (i.e.

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

DO NOT

• Do not operate machine on hillsides or slopes

exceeding 15

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

slowly and gradually downhill, if possible.

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

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

• Do not mow on wet grass. Reduced traction

could cause sliding.

• Do not try to stabilize the machine by putting

your foot on the ground.

• Do not use a grass catcher on steep slopes.

Heavy grass bags could cause loss of control or overturn the machine.

°.

Children

Tragic accidents can occur if the operator is not alert to the presence of children. Children are often attracted to the machine and the mowing activity. Never assume that children will remain where you last saw them. The following requirements must be followed to prevent injury to children.

• Avoid starting or stopping on a slope. If tires

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

• When operating machine on slopes, banks or

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

• When operating a machine with ROPS (roll over

protection) always use seat belt.

• Be certain that the seat belt can be released

quickly if the machine is driven or rolls into ponds or water.

1. Keep children out of the mowing area and under

the watchful care of another responsible adult.

2. Be alert and turn the machine off if children

enter the area.

3. Before and while backing, look behind and down

for small children.

4. Never carry children. They may fall off and be

seriously injured or interfere with safe machine operation.

Page 8

Safety

5. Never allow children to operate the machine.

6. Use extra care when approaching blind corners,

shrubs, trees, the end of a fence or other objects that may obscure vision.

Service

1. Stop the engine and disconnect spark plug

wire(s) before performing any service, repairs, maintenance or adjustments.

2. Use extra care when handling gasoline and other

fuels. They are flammable and vapors are explosive.

A. Use only an approved container. B. Never remove the gas cap or add fuel when

the engine is running. Allow the engine to

cool before refueling. Do not smoke. C. Never refuel the machine indoors. D. Never store the machine or fuel container

inside where there is an open flame, such as

near a water heater or furnace.

9. Mower blades are sharp and can cut. Wrap the

blade(s) or wear gloves, and use extra caution when servicing them.

10. Use only genuine replacement parts to ensure

that original standards are maintained.

11. Check brake operation frequently. Adjust and

service as required.

12. Battery acid is poisonous and can cause burns.

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

13. Battery gases can explode. Keep cigarettes,

sparks and flames away from battery.

14. Hydraulic fluid escaping under pressure can

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

15. Never modify ROPS (roll over protection)

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

3. Never run a machine inside a closed area.

4. Keep nuts and bolts tight, especially the blade

attachment bolts. Keep equipment in good condition.

5. Never tamper with safety devices. Check safety

systems for proper operation before each use.

6. Keep the machine free of grass, leaves, or other

debris build-up. Clean up oil or fuel spillage. Allow the machine to cool before storing.

7. Stop and inspect the equipment if you strike an

object. Repair, if necessary, before restarting.

8. Grass catcher components are subject to wear,

damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer’s recommended parts, when necessary.

16. Never remove radiator cap when the engine is

hot. Allow engine to cool before removing cap.

17. Never place hands and clothing in cooling fan

and drive shaft area while engine is running. The cooling fan turns on and off when cooling is needed. Shut off engine and remove key before performing maintenance.

Page 9

Safety

Slope

Read all safety instructions on pages 4–6.

Chart

Page 10

Page 11

Safety

and Instruction Decals

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

ON RIGHT SIDE OF HEIGHT OF

CUT PLA

(Part No E633345)

OP OF CONSOLE UNDER SEA

(Part No. E513747)

ON LEFT SIDE OF

HEIGHT–OF–CUT PLA

(Part No E633706)

ON T

OP OF CONSOLE LEFT

AND RIGHT SIDES

(Part No. E633354)

BELOW CENTER OF CONSOLE

(Part No. E633346)

LEFT SIDE OF CONSOLE

(Part No. 98–4387)

Page 12

Safety

UNDER FOOTREST

(Part No. E633766)

BELOW FRONT OF

ENGINE COVER

(Part No. E633771)

ON RUBBER FLAP BEHIND SEA

(Part No. E513748)

ON RUBBER FLAP

BEHIND SEA

(Part No. E643252)

WARNING

ROTATING

STOP ENGINE BEFORE

REACHING UNDERNEA

ON CONSOLE AND RUBBER

FLAP BEHIND SEA

(Part No. E633462)

MECHANICAL

DEVICES!

E643252

ON CONTROL P

(Part No. 99–461

ANEL

Page 13

LEFT SIDE GAS T

(Part No. 99–4612)

ANK

ON T

OP OF HYDRAULIC

RESERVOIR

(Part No. E523552)

Safety

ON DECK SUPPORT FRAME

(Part No. E633818)

ON RADIATOR TRIM PLA

(Part No. 65–2690)

ON HYDRAULIC RESER

MOUNTING BRACKET

(Part No. E513929)

ON RADIAOR F

AN MOUNTING PLA

(Part No. E643253)

CAUTION

ROTATING

OP ENGINE BEFORE

REACHING UNDERNEA

BLADES!

E643253

VOIR

TH.

Page 14

Safety

ON RIGHT SIDE OF MOWER

(Part No. 66-1340)

ON LEFT SIDE OF MOWER

(Part No. 43-8480)

UNDER DEFLECTOR

(Part No. 66-6380)

ON DEFLECTOR

(Part No. 54-9220)

UNDER

FOOTREST AND (3)

UNDER PULLEY COVERS

(Part No. 98–5954)

(2) ON BELT COVERS

(Part No. 67-5360)

ON TOP CENTER OF MOWER

(Part No. 98-3799)

NEXT TO ANTIĆSCALP ROLLER

(Part No. 98-3798)

ON LEFT FRONT OF MOWER

(Part No. 93-7818)

115–149 NSm

85–110

SLbs

Page 15

Gasoline and Oil

Recommended

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

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

POTENTIAL HAZARD

Gasoline

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Use a funnel and fill the fuel tank outdoors,

in an open area, when the engine is cold. Wipe up any gasoline that spills.

• Do not fill the fuel tank completely full.

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

• Never smoke when handling gasoline, and

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

• Store gasoline in an approved container

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

POTENTIAL HAZARD

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

OID THE HAZARD

• Always place gasoline containers on the

ground away from your vehicle before filling.

• Do not fill gasoline containers inside a

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

• When practical, r

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

emove gas–power

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used,

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

Page 16

Gasoline and Oil

Stabilizer/Conditioner

Add the correct amount of gas stabilizer/conditioner to the gas. Using a stabilizer/conditioner in the machine:

• Keeps gasoline fresh during storage

• Cleans the engine while it runs

• Eliminates gum-like buildup in the fuel system,

which causes hard starting

IMPORTANT: Never use fuel additives containing methanol or ethanol.

Filling

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

2. Clean around each fuel tank cap and remove the

3. Install fuel tank caps securely. Wipe up any

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 38.

the Fuel T

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

gasoline that may have spilled.

ank

Engine Oil Level

Page 17

Assembly

Loose

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

DESCRIPTION QTY. USE

Rear Wheels Retaining rod

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

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

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

Parts

s Manual

2 1

1 1

1 1 4 4

2 1 1 1 1

Install wheels to traction unit

Install seat rod

Install motion control levers

Read before operating machine

Fill out and return to T

oro

Page 18

Assembly

Install

Drive Wheels

1. Uncrate mower.

2. Remove wheel nuts from rear wheel hubs.

3. Align holes. Mount drive wheels with the valve

stem to the outside of the traction unit.

4. Secure using wheel nuts provided. Torque to

95ft–lbs (128 NSM).

Tire

Pressure

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

Pressure: 13 psi (90 kPa)

Install

Seat Retaining Rod

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

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

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 mounting hardware (Fig. 2).

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

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

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

freely.

Figure 1

1. Valve

stem

m–1872

m–3750

Figure 2

1. L

end of retaining rod

Locknut 5/16”

Bolt 5/16–18 x 1” (26 mm)

Page 19

Assembly

Install

Motion Control Levers

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

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

2. Place the levers (with the mounting plate toward

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

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. 3).

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

while in the drive position (Fig 4) (levers rotated in as far as possible) make adjustments by moving the levers 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.

Figure 4

1. Mounting

Bolt 3/8–18 x 1” (26 mm)

plate

Figure 3

Spring washer 3/8”

m–3751

Page 20

Assembly

Activate

the Battery

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

1. Tilt seat up and remove battery.

2. First disconnect the negative battery cable and

ground wire from the negative (–) battery terminal.

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

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

4. Remove battery hold down clamp. IMPORTANT: Be careful not to damage the

long vent tube when removing the battery box.

POTENTIAL HAZARD

• Battery electrolyte contains sulfuric acid

which is a deadly poison and it causes severe burns.

5. Remove filler caps from the battery. Slowly pour

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

m–1262

Figure 5

1. Filler

2. Electrolyte

caps

Lower part of the tube

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

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

WHAT CAN HAPPEN

• If you carelessly drink electrolyte you could

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

HOW TO AV

OID THE HAZARD

• Do not drink electrolyte and avoid contact

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

1. Positive

Negative post

post

m–1254

Figure 6

Charger red (+) wire

Charger black (–) wire

Page 21

Install Battery

Assembly

POTENTIAL

• Charging battery pr

HAZARD

oduces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

7. When the battery is fully charged, disconnect the

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

8. Slowly pour electrolyte into each cell until the

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

1. Position battery in tray with terminal posts

toward the engine (Fig. 7).

2. Install the positive (red) battery cable to positive

(+) battery terminal first, then the negative battery cable and ground wire to the negative (–) battery terminal.

3. Secure cables with (2) 1/4 x 3/4” (19 mm) bolts

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

4. Slide the red terminal boot onto the positive

(red) battery cable.

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

and (2) 1/4” washers and (2) 1/4” wing nuts (Fig. 7). Do not over tighten.

6. Position drain tube away from belts and other

parts to prevent corrosion.

9 5

1. Battery

2. Terminal

6. Bolt

boot Positive battery cable Negative battery cable Ground wire

1/4–20 x

Figure 7

3/4” (19 mm)

7. Washer

Locknut 1/4”

Battery clamp

10. J-bolts

11.

Wing nut 1/4”

12.

Drain T

6 7

m–3752

1/4”

ube

Page 22

Assembly

Check

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 38.

Check

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

Check

Engine Oil Level

Side Discharge Chute

the Leveling of Mower

Deck

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

Refer to Mower Leveling and Compression Spring Adjustment in the Maintenance section on page 55.

Cooling

Checking Radiator Coolant

POTENTIAL

• Coolant is hot and pressurized.

• Radiator and surrounding parts are hot.

WHAT CAN HAPPEN

• Discharge of hot pressurized coolant or

touching hot radiator can cause severe burns.

HOW TO AV

• Do not remove the radiator cap when the

engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap.

• Do not touch radiator and surrounding

parts that are hot.

System

HAZARD

OID THE HAZARD

Check the cooling system level before engine is first started.

Fluid Type: 50/50 mix of permanent anti–freeze (ethylene glycol) and water.

Cooling System Capacity: 4 qt. (3.8 l)

Page 23

Assembly

POTENTIAL HAZARD

• Rotating fan turns on and off unexpectedly

and can cause injury.

• Rotating shaft can cause injury.

WHAT CAN HAPPEN

• Fingers, hands or loose clothing can get

caught by rotating fan and drive shaft.

HOW TO AV

OID THE HAZARD

• Do not operate the machine without the

covers in place.

• Keep fingers, hands and clothing clear of

rotating fan and drive shaft.

• Shut off the engine and remove the ignition

key before performing maintenance.

POTENTIAL HAZARD

• Engine coolant is toxic.

WHAT CAN HAPPEN

• Swallowing coolant can cause poisoning.

1. Radiator

Cap

Figure 8

Antifreeze Overflow Bottle



HOW TO AV

OID THE HAZARD

• Do not swallow.

• Keep out of reach from children and pets.

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Tilt seat up and tilt engine hood forward.

3. With the engine cool, remove the radiator cap

(Fig. 8).

4. If coolant level is low, add 50/50 mixture of

permanent anti–freeze and water until completely full without overflowing.

5. Reinstall radiator cap. Completely seat cap by

pushing down and turning until it stops.

6. Add 50/50 coolant mix to overflow bottle and

fill to indicator line on the bottle, if required (Fig. 8).

Page 24

Assembly

Hydraulic

System

Checking the Hydraulic Fluid

Check the hydraulic fluid level before engine is first started.

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

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

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

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 9).

3. Remove cap from filler neck. Look inside to

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

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

below the top of baffle.

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

purge out of the system.

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

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

baffle when fluid is warm (Fig. 9).

7. Install cap on filler neck.

Figure 9

1. Cap

2. Baffle

POTENTIAL

HAZARD

3. Fluid

level-Full

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

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

HOW TO AV

OID THE HAZARD

• 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.

M-4280

Page 25

Operation

Think

Safety First

Please carefully read all the safety instructions on pages 3–8. Knowing this information could help you, your family, pets or bystanders avoid injury.

Controls

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

Parking Brake

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

Setting the Parking Brake

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

the neutral lock position.

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

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

POTENTIAL HAZARD

• Parking break may not hold machine if

parked on slope.

WHAT CAN HAPPEN

• Unattended unit may roll away and cause

personal injury or property damage.

1. Ignition

4. Throttle

5. Choke

switch Motion control lever Parking brake lever

HOW TO AV

OID THE HAZARD

• Do not park on slopes unless wheels are

chocked or blocked.

Figure 1

Power take of

Height-of-Cut lever

Fuel cap

Fuel shut of

10.

Hour meter



f (PT

f lever

Page 26

Operation

Releasing the Parking Brake

1. Push forward and down on the parking brake

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

Figure 2

1. Parking

Starting

brake-ON

Parking brake-OFF

and Stopping

Brake Stop

m–4163

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

When engines starts, release key (Fig. 6).

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

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

(Fig. 4). If the engine stalls or hesitates, move the choke back to “ON” for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.

Figure 3

1. PTO-On

2. PTO-Off

m–4201

Figure 4

1. Choke–On

2. Choke–Off

m–2719

the Engine

Starting

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

neutral locked position.

2. Set the parking brake; refer to Setting the

Parking Brake, page 23.

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

(Fig. 3).

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

starting a cold engine (Fig. 4). Note: A warm or hot engine may not require

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

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

before starting a cold engine (Fig. 5).

Figure 5

1. Throttle–Fast

2. Throttle–Slow

m–2720

M-4268

Figure 6

1. Off

2. Run

3. Start

Page 27

Operation

Stopping

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

2. Turn the ignition key to “OFF” and remove

(Fig. 6). Note: If the engine has been working hard or

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

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

of someone accidentally starting the machine before transporting or storing machine.

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

transporting or storing machine.

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

Operating

the Power T

ake Off

(PTO)

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

Engaging the PTO

1. Release pressure on the traction control levers

and place in neutral.

2. Release the parking brake, page 24.

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

engage (Fig. 7).

m–4201

POTENTIAL HAZARD

• Someone could move or attempt to operate

the tractor while it is unattended.

• Fuel pump could stay operating.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the tractor.

• Fuel leakage could occur if there is a leak in

fuel line.

HOW TO AV

•

Always r parking brake when leaving the machine, even if just for a few minutes.

OID THE HAZARD

emove the ignition key and set the

Figure 7

1. PTO

– Of

f2.PT

O – On

Disengaging the PTO

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

position (Fig. 7).

Page 28

Operation

The

Safety Interlock System

Understanding the Safety Interlock System

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

• You are sitting on the seat

• The parking brake is “ENGAGED”

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

• The motion control levers are in neutral locked

position

The safety interlock system also is designed to stop the engine when the traction controls are moved from the locked position with the parking brake “ENGAGED” or if you rise from the seat when the PTO is “ON” 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” parking brake

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

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

and move PTO “OFF”. Move either motion control lever (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” parking brake,

move PTO switch “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” parking brake,

move PTO switch “OFF” and move the motion control levers to neutral lock position. Now start the engine. While the engine is running, center either motion control and move (forward or reverse); the engine should stop.

5. Sitting on the seat, “DISENGAGE” parking

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

Page 29

Operation

Driving

Forward or Backward

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

Forward

1. Release the parking brake; refer to Releasing the

Parking Brake, page 24.

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

3. To go forward, slowly push the motion control

levers forward (Fig. 8). Note: Engine will kill if traction control

levers are moved with parking brake engaged.

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

Backward

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

2. To go backward, slowly pull the motion control

levers rearward (Fig. 8).

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

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

To stop push the motion control levers to neutral.

Stopping

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

the Machine

To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 8).

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

To stop pull the motion control levers to neutral.

1. Motion

control

lever-neutral lock position Center un-lock position

Figure 8

m–2715

3. Forward

4. Backward

POTENTIAL HAZARD

• Someone could move or attempt to operate

the tractor while it is unattended.

• Fuel pump could stay operating.

WHAT CAN HAPPEN

• Children or bystanders may be injured if

they use the tractor.

• Fuel leakage could occur if there is a leak in

fuel line.

HOW TO AV

•

Always r parking brake when leaving the machine, even if just for a few minutes.

OID THE HAZARD

emove the ignition key and set the

Page 30

Operation

Instruments

Hour Meter

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

m–3077

Figure 9

1. Hour

meter

Fuel Tanks

Adjusting

Height-of-Cut

The height-of-cut is adjusted from 1-1/2” to 5” (38 to 127 mm) in 1/4” (6 mm) increments by relocating clevis pin in different hole locations.

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

position (also the 5” (127 mm) cutting height position) (Fig. 11).

2. To adjust, remove hairpin cotter and clevis pin

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

3. Select hole in height-of-cut bracket

corresponding to the height-of-cut desired. Lift handle to transport position, insert clevis pin (Fig. 11).

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

5. Move lever to selected height.

The unit has two fuel tanks, one located on the left side and 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. 10).

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

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

Figure 10

1. Shut

f valve

1. Height

Clevis Pin

of cut lever

Figure 1

Hairpin Cotter



Page 31

Operation

Adjusting

Anti-Scalp Rollers

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

Outer Rollers

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

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

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

and spring disk while holding stud with wrench (Fig. 12).

Note: Do not remove the wheel nut and

washer (Fig. 12).

3. Select hole so gage wheel is positioned to the

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

4. Reinstall the flange nut and spring disk

(Fig. 12).

Center Rollers

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

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

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

flange nut (Fig. 13).

3. Select hole so gage wheel is positioned to the

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

Note: Do not adjust rollers to support the

deck.

4. Reinstall the bolt, center rollers and flange nut

(Fig. 13).

5. Repeat adjustment on other gage wheels.

Figure 12

1. Gage

2. Stud

Wheel

Spring Disk

Flange Nut

Wheel nut and washer Do Not Remove.

Figure 13

1. Center

2. Flange

m–4167

Rollers and Spacer Nut

3. Bolt

m–4124

Page 32

Operation

Positioning

the Seat

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

1. To adjust, move the lever sideways to unlock

seat (Fig. 14).

2. Slide the seat to the desired position and release

lever to lock in position.

m–3655

Figure 14

1. Adjustment

knob

.Pushing

the Machine by Hand

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

To Push the Machine

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

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

Rotate the by-pass valves counterclockwise 1 turn to push. This allows hydraulic fluid to by-pass the pump enabling the wheels to turn (Fig. 15).

IMPORTANT: Rotate by-pass valves a maximum of 2 turns so the valves do not come out of the body causing fluid to run out.

3. Disengage parking brake before pushing.

To Operate the Machine

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

operate machine (Fig. 15). Note: The machine will not drive unless

by-pass valves are turned in.

Figure 15

1. By-pass

valve

Page 33

Operation

Tips

for Mowing Grass

Fast Throttle Setting

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

Cutting a Lawn for the First Time

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

Cutting Speed

To improve cut quality, use a slower ground speed in certain conditions.

Avoid Cutting Too Low

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

Long Grass

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

When Stopping

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.

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.

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 immediately with a genuine T blade.

. If a blade is damaged or worn, replace it

ORO replacement

Page 34

Maintenance

Service

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

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

ires—check pressure Chipped Surfaces—paint Cutting Blades–check Blade Spindle Bearings–grease Mower Housing–clean Engine Coolant–check Engine Coolant–change Engine Cooling System–clean* Engine Cooling System–check Cooling System Hoses–check *

More often in dusty

Interval Chart

Operation

, dirty conditions

Each

Use8Hours25Hours50Hours

Initial Initial X X

X X

Initial X X

X X

X X X X X

X X

100

Hours

X X X X

X X

200

Hours

X X

400

Hours

X X

Storage Service

Page 35

POTENTIAL HAZARD

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

WHAT CAN HAPPEN

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

Maintenance

HOW TO AV

OID THE HAZARD

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

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

Cutting

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

Blades

. If a blade is damaged

Before Inspecting or Servicing the Blades

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

POTENTIAL HAZARD

• A blade that is worn or damaged could

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

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

OID THE HAZARD

• Periodically inspect the blade for wear and

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

Page 36

Maintenance

Inspecting the Blades

1. Inspect the cutting edges (Fig 16). If the edges

are not sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 35.

2. Inspect the blades, especially the curved area

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

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 17). Measure from a level surface to the cutting edge of the blades (Fig.

18). Note this dimension.



m–1078

Figure 17

1. Cutting

Curved Area

Edge

Figure 16

3. W

ear/slot Forming

m–151

 

   

 

Figure

m–2539

2. Rotate the opposite ends of the blades forward.

Measure from a level surface to the cutting edge of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8” (3 mm). If this dimension exceeds 1/8” (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 36.

Page 37

POTENTIAL HAZARD

• A blade that is bent or damaged could

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

WHAT CAN HAPPEN

• Pieces of blade that may be thrown could

seriously injure or kill you or bystanders.

HOW TO AV

•

Always r

OID THE HAZARD

eplace bent or damaged blade with

a new blade.

• Never file or create sharp notches in the

edges or surfaces of blade.

Removing the Blades

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

ORO replacement blades.

Maintenance

Sharpening the Blades

POTENTIAL

HAZARD

• When sharpening blade, pieces of blade

could be accidentally thrown.

WHAT CAN HAPPEN

• Thrown objects can cause serious eye

injury.

HOW TO AV

OID THE HAZARD

• Wear proper eye protection when

sharpening blade.

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

ends of the blade (Fig. 19). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

POTENTIAL HAZARD

• Blade is sharp.

WHAT CAN HAPPEN

• Contact with sharp blade can cause serious

personal injury.

HOW TO AV

OID THE HAZARD

• Wear gloves or wrap sharp edges of the

blade with a rag.

1. Hold the blade end using a rag or thickly-padded

glove. Remove the blade bolt, spring disk and blade from the spindle shaft (Fig. 21).

m–1854

Figure 19

1. Sharpen

at original angle

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

blade balancer (Fig. 20). 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. NO TAG). Repeat this procedure until the blade is balanced.

Figure 20

1. Blade 2. Balancer

m–1855

Page 38

Maintenance

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 21). IMPORTANT: The curved part of the blade

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

2. Install the spring disk and blade bolt. The spring

disk cone must be installed toward the bolt head. (Fig. 21). Torque the blade bolt to 85–110 ft-lb (115–150 NSm).

3 5

1. Sail

2. Blade

Spring Disk

Area of Blade

Figure 21

Blade Bolt Cone T

owards Bolt Head

M-4226

Air

Cleaner

Paper Element:

• Clean after 50 operating hours.

• Replace after 300 operating hours.

Note: Service the air cleaner more frequently

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

Removing Paper Element

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

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

2. Tilt seat up and tilt engine cover forward.

3. Clean around the air cleaner to prevent dirt from

getting into the engine and causing damage. Loosen retaining clips and remove air cleaner cover (Fig. 22).

M-4382

Figure 22

1. Retaining

Air cleaner cover

Clip

Air Filter

4. Carefully remove filter from compartment (Fig.

22).

Page 39

Maintenance

Cleaning Paper Elements

1. Paper Element

A. Lightly tap the element on a flat surface to

remove dust and dirt (Fig. 23).

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

and damage to the rubber seal.

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

Engine

Oil

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

Note: Change oil more frequently when

operating conditions are extremely

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

• 1.9 qt. (1.8 l) – When oil filter is removed.

• 1.6 qt. (1.5 l) – When oil filter is not removed.

Viscosity: See table below

USE THESE SAE VISCOSITY OILS



Figure 23

1. Paper

element

Rubber seal

Installing Paper Elements

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

1. Carefully slide the element into the compartment

(Fig. 22).

2. Place the air cleaner cover onto compartment

and latch retaining clips (Fig. 22).

m–4292

Page 40

Maintenance

Checking Oil Level

Note: Check oil when engine is cold.

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

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

2. Clean around the oil dipstick so dirt cannot fall

into the filler hole and damage the engine (Fig. 24).

3. Pull the oil dipstick out and wipe the metal end

clean (Fig. 24).

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

Pull the dipstick out and look at the metal end (Fig. 24). If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the “FULL” mark.

IMPORTANT: Do not overfill the crankcase with oil because the engine may be damaged. Do not run engine with oil below the low mark because the engine may be damaged.

Changing/Draining Oil

Replace the oil every 100 hours.

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

warms the oil so it drains better.

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

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

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

drain cap (Fig. 25).

4. When oil has drained completely, install the

drain cap. Note: Dispose of the used oil at a certified

recycling center.

m–4377

1. Oil

Filler tube

dipstick

Figure 24

Metal end

M-4381

1. Oil

Figure 25

drain cap

M-4380

5. Slowly pour approximately 80% of the specified

amount of oil specified, page 37, into the filler tube (Fig. 24). Now check the oil level; refer to Checking Oil Level, page 38. Slowly add additional oil to bring to “FULL” mark on dipstick.

Page 41

Maintenance

Change Oil Filter

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

Note: Change oil filter more frequently when

operating conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to

Changing/Draining Oil, page 38.

2. Remove the old filter and wipe the filter adapter

(Fig. 26) gasket surface.

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

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

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

on the replacement filter (Fig. 26).

Cooling

System

Checking Radiator Coolant

POTENTIAL

HAZARD

• Coolant is hot and pressurized.

• Radiator and surrounding parts are hot.

WHAT CAN HAPPEN

• Discharge of hot pressurized coolant or

touching hot radiator can cause severe burns.

HOW TO AV

OID THE HAZARD

• Do not remove the radiator cap when the

engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap.

• Do not touch radiator and surrounding

parts that are hot.

1. Oil

filter

2. Gasket

Figure 26

3. Adapter

m–1256

5. Install the replacement oil filter to the filter

adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 26).

6. Fill the crankcase with the proper type of new

oil; refer to Changing/Draining Oil, page 38.

Check the cooling system level daily. Fluid Type: 50/50 mix of permanent antifreeze

(ethylene glycol) and water. Cooling System Capacity: 4 qt. (3.8 l)

Page 42

Maintenance

POTENTIAL HAZARD

• Rotating fan turns on and off unexpectedly

and can cause injury.

• Rotating shaft can cause injury.

WHAT CAN HAPPEN

• Fingers, hands or loose clothing can get

caught by rotating fan and drive shaft.

HOW TO AV

OID THE HAZARD

• Do not operate the machine without the

covers in place.

• Keep fingers, hands and clothing clear of

rotating fan and drive shaft.

• Shut off the engine and remove the ignition

key before performing maintenance.

POTENTIAL HAZARD

• Engine coolant is toxic.

WHAT CAN HAPPEN

• Swallowing coolant can cause poisoning.

HOW TO AV

OID THE HAZARD

• Do not swallow.

• Keep out of reach from children and pets.

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Tilt seat up and tilt engine hood forward.

3. With the engine cool, remove the radiator cap

(Fig. 27).



Figure 27

1. Radiator

Antifreeze Overflow Bottle

Cap

Radiator Core and Screen

Cleaning Cooling System

Clean the cooling system daily before each use.

1. Position machine on a level surface, stop the

engine and set the parking brake.

IMPORTANT: Before starting engine clean grass fr Check more often in dry conditions.

2. Tilt seat up and raise rubber flap above drive belt

compartment.

3. Remove debris from drive belt compartment and

hydraulic pumps.

4. Remove debris from screen on engine cover.

5. Tilt engine cover forward.

om pump drive belt compartment.

4. If coolant level is low, add 50/50 mixture of

permanent antifreeze and water until completely full without overflowing.

5. Reinstall radiator cap. Completely seat cap by

pushing down and turning until it stops.

6. Add 50/50 coolant mix to overflow bottle and

fill to indicator line on the bottle, if required (Fig. 27).

6. Remove debris from radiator core and engine

(Fig. 27).

IMPORTANT: Do not damage radiator cooling fins.

7. Inspect seals on engine cover and replace if

needed.

8. Close engine cover and tilt seat back.

Page 43

Maintenance

Changing Engine Coolant

Change engine coolant every 400 hours.

POTENTIAL HAZARD

• Rotating fan turns on and off unexpectedly

and can cause injury.

• Rotating shaft can cause injury.

WHAT CAN HAPPEN

• Fingers, hands or loose clothing can get

caught by rotating fan and drive shaft.

HOW TO AV

OID THE HAZARD

• Do not operate the machine without the

covers in place.

• Keep fingers, hands and clothing clear of

rotating fan and drive shaft.

• Shut off the engine and remove the ignition

key before performing maintenance.

3. With engine cool, drain coolant by loosening the

drain cock in the right rear corner (Fig. 28)

4. The engine block may be drained by removing

the radiator hose and/or drain plugs from the engine block (Fig. 29).

Note: The drain plugs may be accessed from

the back of the machine and are located

in both cylinders. They are hex heads

and black in color (Fig. 29).

5. Re–install all drain plugs, radiator hose and

tighten drain cock.

POTENTIAL HAZARD

• Coolant is hot and pressurized.

• Radiator and surrounding parts are hot.

WHAT CAN HAPPEN

• Discharge of hot pressurized coolant or

touching hot radiator can cause severe burns.

HOW TO AV

OID THE HAZARD

• Do not remove the radiator cap when the

engine is hot. Always allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand before removing the radiator cap.

• Do not touch radiator and surrounding

parts that are hot.

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Tilt seat up and tilt engine hood forward.

Figure 28

1. Drain

Cock (Right rear of

Radiator)

Plug (From engine

block)

Figure

6. Drain coolant from overflow bottle.





Page 44

Maintenance

7. Remove the radiator cap and add 50/50 mixture

of permanent antifreeze and water until completely full.

8. Wait 2 minutes and check if coolant stays up to

full level. Add 50/50 mixture of permanent antifreeze and water until completely full, if required. Repeat until the coolant stays up to the full level.

9. With the radiator cap off, tilt the engine cover

down and put the seat down. Start the engine. Run engine until it is warm.

10. Shut off engine.

11. Tilt seat up and tilt engine hood forward.

Recheck the coolant level after the engine has cooled down and replenish, if required.

12. Reinstall radiator cap. Completely seat cap by

pushing down and turning until it stops.

13. Add 50/50 coolant mix to overflow bottle and

fill to indicator line on the bottle.

Cooling System Inspection

Inspect the radiator and the hoses initially and after first 8 hours.

Inspect the radiator and the hoses every 200 hours.

1. Check hoses and radiator for cracks, dents and

fractured seams. Repair or replace damaged hoses or radiator.

14. Check for any leaks in the cooling system.

Check after first 8 hours of changing coolant.

15. Close engine cover and tilt seat back.

Figure 30

1. Radiator

Cap

Antifreeze Overflow Bottle



Page 45

Maintenance

Spark

Plug

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

Type: NGK BMR 4A (or equivalent) Air Gap: 0.026 in. (0.65 mm)

Removing the Spark Plug(s)

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

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

2. Clean around the spark plug(s) to prevent dirt

from falling into the engine and potentially causing damage. Pull the wire(s) off the spark plug(s) (Fig. 31).

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

Checking the Spark Plug

1. Clean the electrodes by scraping or with ba wire

brush to remove carbon deposits and wetness (Fig. 32).

1. Inspect spark plug (Fig. 32).

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

2. Check the gap between the center and side

electrodes (Fig. 32). Bend the side electrode (Fig. 32) if the gap is not correct.

1. Center

Side electrode

Figure

electrode insulator

Air gap (not to scale)

0.024

–

0.028in. (0.6

0.7mm)

m–3215

1. Spark

plug wire

Figure 31

Spark plug

Installing the Spark Plug(s)



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

set correctly.

2. Tighten the spark plug(s) to 17 ft-lb (23 N.m).

3. Push the wire(s) onto the spark plug(s) (Fig. 31).

Page 46

Maintenance

Greasing

Lubricate the machine when shown on the CHECK SERVICE REFERENCE AID decal (Fig. 33). Grease more frequently when operating conditions are extremely dusty or sandy.

Grease Type: General-purpose grease.

and Lubrication

How to Grease

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

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

2. 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.

Where to Add Grease

Lubricate the grease fittings as shown on the CHECK SERVICE REFERENCE AID decal (Fig. 33).

Figure 33

4. Wipe up any excess grease.

Grease Front Castor Pivots

Lubricate the front castor pivots once a year.

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

into hole.

2. Pump grease into zerk until it oozes out around

top beraring.

3. Remove grease zerk in hole. Reinstall hex plug

and cap.

Where to Add Light Oil or Spray Lubrication

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

• Seat switch actuator.

• Brake handle pivot.

• Brake rod bushings.

• Motion control bronze bushings.

Page 47

Tire

Pressure

Fuel

Maintenance

Filter

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

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

m–1872

Figure 34

1. Valve

stem

Replace the fuel filter after every 300 operating hours or yearly, whichever occurs first.

Replacing the Fuel Filter

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

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

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

2. Close fuel shut–off valve on console.

3. Tilt seat forward to access fuel filter.

4. Squeeze the ends of the hose clamps together

and slide them away from the filter (Fig. 35).

5. Remove the filter from the fuel lines.

6. Install a new filter and move the hose clamps

close to the filter (Fig. 36).

7. Wipe up any spilled fuel.

8. Open fuel shut-off valve on console.

Figure 35

1. Filter 2. Hose

clamp



Page 48

Maintenance

Fuel Tank

Draining The Fuel Tank

POTENTIAL

• In certain conditions gasoline is extremely

flammable and highly explosive.

WHAT CAN HAPPEN

• A fire or explosion from gasoline can burn

you, others, and cause property damage.

HOW TO AV

• Drain gasoline from the fuel tank when the

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

• Never drain gasoline near an open flame or

where gasoline fumes may be ignited by a spark.

• Never smoke a cigarette, cigar or pipe.

HAZARD

OID THE HAZARD

4. Pull the fuel line off fuel filter (Fig. 36). Open

fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new

fuel filter because the fuel tank is empty.

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

hose clamp close to the fuel filter to secure the fuel line (Fig. 36).

m–3717



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

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

2. Close fuel shut–off valve (Fig. 36).

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

it up the fuel line away from the fuel filter (Fig. 36).

1. Fuel

Fuel filter

shut-of

f valve

Figure 36

Hose clamp Fuel line

Page 49

Maintenance

Hydraulic

System

Checking the Hydraulic Fluid

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.

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

System Capacity: 2.1 qt. (2.0 l)

1. Position machine on a level surface, stop the

engine and set the parking brake.

2. Clean area around filler neck of hydraulic tank

(Fig. 37).

3. Remove cap from filler neck. Look inside to

check if there is fluid in the reservoir. (Fig. 37).

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

below the top of baffle.

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

purge out of the system.

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

raise level to top of the baffle, if required.

Figure 37

1. Cap

2. Baffle

POTENTIAL

HAZARD

3. Fluid

level-Full

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

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

HOW TO AV

OID THE HAZARD

• 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.

M-4280

Note: Fluid level should be to the top of the

baffle when fluid is warm (Fig. 37).

7. Install cap on filler neck.

Page 50

Maintenance

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 8 operating hours.

• After every 200 operating hours.

• Use summer filter above 32_F (0_C)

Use winter filter below 32_F (0_C)

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

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

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

2. Tilt seat forward to access filter.

3. Remove hydraulic reservoir cap and temporarily

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

7. Remove plastic bag from tank opening and allow

filter to fill with hydro fluid.

8. 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. 39).

9. Clean up any spilled fluid.

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 49.

11. Check fluid level in hydraulic tank and add to

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

4. Place drain pan under filter, remove the old filter

and wipe the filter adapter gasket surface clean (Fig. 38).



Figure 38

1. Hydraulic

filter

5. Apply a thin coat hydro fluid to the rubber

gasket on the replacement filter (Fig. 39).

1. Hydraulic

2. Gasket

filter

m–1256

Figure 39

3. Adapter

6. Install replacement hydraulic filter onto the filter

adapter. Do not tighten.

Page 51

Maintenance

Bleeding Hydraulic System

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

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

ground and support with jack stands.

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

traction on one side and spin the wheel by hand.

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

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

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.

POTENTIAL HAZARD

• Hydraulic fluid escaping under pressure

can penetrate skin and cause injury.

WHAT CAN HAPPEN

• Fluid accidentally injected into the skin

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

HOW TO AV

OID THE HAZARD

• 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.

Page 52

Maintenance

Adjusting

Motion Controls

Adjusting Handle Neutral

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

Note: Motion control levers must be installed

correctly. See Install Motion Control Levers on page 17.

1. Stop engine, remove ignition key and tilt seat

forward.

2. Begin with either the left or right motion control

lever. Move lever to the neutral (but not locked) position and pull lever back until the clevis pin (on arm below pivot shaft) contacts the end of the slot (just beginning to put pressure on spring) (Fig. 40).

3. Check where lever is relative to notch in console

(should be centered allowing lever to pivot outward to the neutral lock position) (Fig. 40).

1. Neutral

Clevis pin in slot

3. Nut

4. Bolt

lock position

Figure 40

Pump rod

Double nuts

Jam Nut

Adjusting Hydraulic Pump Neutral

Note: Adjust handle neutral first. That has to

be correct before the following adjustment can be made.

m–3800

4. If adjustment is needed, loosen the nut against

the yoke.

5. Apply slight rearward pressure on the motion

control lever, turn the head of the adjustment bolt in the appropriate direction until lever is centered in neutral lock position (keeping rearward pressure on the lever will keep the pin at the end of the slot and allow the adjustment bolt to move the lever to the appropriate position).

6. Tighten nut and jam nut.

7. Repeat on opposite side of unit.

8. This adjustment must be made with drive wheels

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

POTENTIAL HAZARD

• Engine must be running so motion control

adjustment can be performed.

WHAT CAN HAPPEN

• Contact with moving parts or hot surfaces

may cause personal injury.

HOW TO AV

OID THE HAZARD

• Keep hands, feet, face, clothing and other

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

9. Slide seat forward, disconnect prop rod and tilt

seat fully forward.

Page 53

Maintenance

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

11. Loosen locknut at ball joint on pump control rod (Fig. 40).

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

threads.

12. Start engine, open throttle 1/2 way and release parking brake. Refer to Starting and Stopping the Engine, page 24.

13. Adjust pump rod length by rotating double nuts on rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 40).

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

Note: Motion control lever must be in neutral

while making any adjustments.

16. Repeat on opposite side of unit. T

against ball joints.

POTENTIAL HAZARD

ighten locknuts

• Electrical system will not perform proper

safety shut off with jumper wire installed.

WHAT CAN HAPPEN

• Contact with moving parts may cause

personal injury.

HOW TO AV

• Remove jumper wire from wir

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

OID THE HAZARD

e harness

• Never operate this unit with jumper

installed and seat switch bypassed.

17. Shut off unit. Remove jumper wire from wire

harness connector and plug connector into seat switch.

15. Open throttle to fast. Make sure wheel remains stopped or slightly creeps in reverse, re-adjust if necessary.

18. Reinstall prop rod and lower seat.

Page 54

Maintenance

Replacing

the Pump Drive Belt

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

1. Pull spring loaded idler down and remove

traction belt from the engine and hydro pump pulleys (Fig. 41). Remove belt between pulleys.

2. Install new belt around engine and hydro pump

pulleys (Fig. 41).

3. Pull spring loaded idler down and align below

traction belt. Release pressure on spring loaded idler (Fig. 41).

Adjustment

Parking Brake

Check parking brake for proper adjustment.

1. Disengage brake lever (lever down).

2. Measure the length of the spring. Measurement

should be 2.75” (70 mm) between washers (Fig. 42).

3. If adjustment is necessary, loosen the jam nut

below the spring and tighten the nut directly below the yoke (Fig. 42). 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 counter–clockwise to lengthen the spring.

5. Engage parking brake, lever up.

6. Measure the distance between the trunnion roller

and the collar on brake rod . Measurement should be 3/16”–1/4” (5–7 mm) (Fig. 42).

Figure 41

7. If adjustment is necessary, loosen the jam nut

directly below the yoke. Turn the bottom rod until the correct measurement is obtained (Fig. 42). Tighten jam nut at yoke

1. Brake

lever Spring 2.75” (70 mm) Adjusting nuts

Figure 42

m–3788

Collar on brake rod 3/16”–1/4’ (5–7 mm) Jam nut and yoke

Page 55

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 –20 amp, blade-type

Alternator –30 amp, blade-type Fan–30 amp, blade-type

1. To gain access to the main fuse just raise seat. To

gain access to the fan and alternator fuses raise seat and tilt engine cover forward .

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

(Fig. 43 and 44).

Maintenance

1. Main-20

1. Fan-30

amp

Figure 43

Figure

Alternator-30 amp

M-4375

m–3653

Page 56

Maintenance

Battery

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

Voltage: 12 v

Checking Electrolyte Level

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

must be up to the lower part of the tube (Fig. 45). Do not allow the electrolyte to get below the plates. (Fig. 45).

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

of distilled water; refer to Adding Water to the Battery, page 54.

IMPORTANT: Do not overfill the battery because electr sever

e corr

olyte (sulfuric acid) can cause

osion and damage to the chassis.

4. Press the filler caps onto the battery.

5. Position drain tube away from belts and other

parts to prevent corrosion.

Charging the Battery

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

1. Check the electrolyte level; refer to Checking

Electrolyte Level, page 54.

2. Remove the filler caps from the battery and

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

1. Filler

caps

Lower part of tube

Figure 45

3. Plates

1262

Adding Water to the Battery

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

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

2. Lift off the filler caps (Fig. 45).

3. Slowly pour distilled water into each battery cell

until the level is up to the lower part of the tube (Fig. 45).

POTENTIAL HAZARD

• Charging the battery pr

oduces gasses.

WHAT CAN HAPPEN

• Battery gasses can explode.

HOW TO AV

OID THE HAZARD

• Keep cigarettes, sparks and flames away

from battery.

Page 57

Maintenance

Mower

Leveling

1. Position mower on a flat surface. Stop the

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

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

needed, adjust to 13 psi (90 kPa)

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

them completely for this adjustment.

4. Raise the deck to the transport position and take

all force off of the two large deck lift springs by loosening nut in front of each spring (Fig. 46).

5. Place two 1-1/2” (38 mm) thick blocks under

rear left and right lower edge of mower. Place one 2” (51 mm) block under front center lower edge

mower

Lower mower to the 1-1/2”

(38 mm) height-of-cut position (Fig. 46).

8. Lift up on four (4) top chain attachment bolts, in

the slots, to take slack out of chains and tighten flange lock nuts

(Deck is still supported by two

rear and one front blocks under mower)

9. If bolts contact the end of slots, shorten or

lengthen rod/swivel assemblies as required, for extra clearance, adjust each side same amount.

Note: When properly adjusted, the front

blade tips will be slightly lower than the rear.

m–4164

Figure 46

1. Transport

position

1-1/2” (38 mm) height-of-cut

6. Loosen four (4) top chain bolts in slots. Check

the length of the rod/swivel assemblies. Distance from outside of rear swivel to outside of front swivel should be

20–1/4” (514 mm) (Fig. 47). Make sure that all four swivels move freely in holes.

m–3747

1. 20-1/4” of swivels

2. T

op chain bolt

(514 mm) outside

Figure 47

Front swivel 10-1/4” (260 mm) spring

compressed

10. Recheck that blocks just fit just under the mower

and that tension on all four chains is approximately equal. Tighten chain attachment bolts securely

11. Measure height of cut. This can be checked with

the same procedure as Checking for Bent Blades on page 34.

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

and tighten securely.

7. If measurement is not 20–1/4” (514 mm) on each

side, adjust by turning nuts on either side of front swivels.

Page 58

Maintenance

Compression Spring Adjustment

1. Raise deck lift lever to the transport position,

(Fig. 46).

2. Springs are compressed so the distance between

the two large washers should be 10-1/4” (260 mm) (Fig. 47).

3. Adjust by turning nut in front of each spring

(Fig. 47). (clockwise will shorten spring, counter–clockwise will lengthen spring)

Greasing

The cutting unit must be lubricated regularly. Refer to the Service Interval Chart on page 32. 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. 48).

3. Grease the fittings on the push arms(Fig. 48).

the Bearings

m–3890

Figure 48

Belt

Inspect all belts every 100 hours.

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

Inspection

or any other damage .Replace damaged belts.

Page 59

Maintenance

Replacing

the Deck Belt

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

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

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

2. Remove the PTO drive belt. Refer to Replacing

the PTO Drive Belt, on page 57.

3. Remove idler spring from idler arm, then remove

the worn deck belt (Fig. 49).

4. Install the new deck belt around the spindle

pulleys, belt guide, the idler pulley, and in the lower groove of the center spindle pulley (Fig. 49).

5. Using a socket and torque wrench, rotate the

idler adjusting nut until torque is 25–30 ft.–lb. (34–41 NDm). Tighten two nuts.

Replacing

the PT

O Drive Belt

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

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

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

2. Remove the clutch retaining strap from machine

frame and unplug clutch terminal from wire harness (Fig. 50).

3. Remove the PTO drive belt (Fig. 50).

4. Place new PTO drive belt over clutch, around

rear idler pulleys and onto mower top center pulley.

Note: Check that belt has only 1/4 twist

between each pulley and idler.

5. Install clutch retaining strap and plug clutch

terminal into main wire harness (Fig. 50).

1. Deck

Idler Arm

Belt

Figure 49

op V

iew

Belt guide Idler Spring

m–3890

6. Reinstall the PTO drive belt. Refer to Replacing

the PTO Drive Belt, page 57.

m–3748

1. Clutch

2. Clutch

clutch T

retaining strap

erminal

Figure 50

4. PT

O belt

Machine Frame

6. Check belt tension. The center bolt of spring

loaded idler must be between the two alignment holes in left support plate (Fig 51).



Page 60

Maintenance

Note: Check position of center bolt in Low

Height of Cut. The center bolt must be at or below the top alignment hole. Check position of center bolt in a High Height of Cut. The center bolt must be at or above the lower adjustment hole (Fig 51).

Figure 51

1. Center idler

bolt, spring loaded

Alignment hole

9. If the fixed idler contacts the end of the

adjustment slot and more belt tension is required, a small change in the lengthen the push arms can be made (Fig. 53).

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

ball joint counterclockwise, one turn at a time. Adjust each side the same amount (Fig. 53).

Note: Increase tension by lengthening the

push arms and decrease tension by shortening push arms.

M-4417

m–3740

7. If adjustment is required, loosen the fixed idler

on right support plate and move up or down in adjustment slot. To relieve belt tension lift up on

1. Push

arm

15” (381 mm) nominal

spring loaded idler.

11. Rotate the belt guide, on rear of the mower, so it

is 1/8”–1/4” (3–7 mm) away from the vertical

m–3746

Figure 52

1. Fixed

Idler

Adjustment slot

side of the PTO belt (Fig. 54).

8. Check belt tension again. The center bolt of

spring loaded idler must be between the two alignment holes in left support plate (Fig 51).

1. Belt

2. PT

guide

O Drive belt

Adjust, if necessary, and tighten all hardware securely.

Figure 53

Figure 54

Jam nut Ball joint

M-4399

1/8”–1/4” (3–7 mm)

Page 61

Maintenance

Replacing

the Alternator Belt

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

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

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

2. Remove the PTO drive belt. Refer to Replacing

the PTO Drive Belt, on page 57.

3. Loosen both upper and lower alternator bolts to

allow alternator to rotate and loosen belt (Fig 55).

4. Remove belt from pulley, alternator and over

clutch pulley (Fig 55).

5. Install new belt.

6. Rotate alternator out away from engine and

tighten lower and upper aletnator bolts (Fig 55). Note: Alternator belt will deflect 1/8” while

applying 5–7 pounds of force, when installed correctly.

Replacing

the Grass Deflector

1. Remove the locknuts, bolts and springs holding

the deflector mounts to the pivot brackets (Fig. 56).

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

the carriage bolts and cone locknuts holding the old brackets to the top of the discharge opening, then install the replacement pivot brackets. Make sure the carriage bolt heads are on the inside of the cutting unit (Fig. 56).

3. Install the deflector mounts onto the pivot

brackets with the bolts, springs and locknuts. Make sure the straight ends of the springs are positioned between the deflector mounts and the grass deflector (Fig. 56).

4. Tighten the locknuts until they contact the pivot

brackets (Fig. 56).

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

7. Reinstall the PTO drive belt. Refer to Replacing

the PTO Drive Belt, page 57.

1. Alternator

2. Upper

Alternator Bolt

Lower Alternator Bolt

Figure 55

5. PT

Alternator Belt

O Drive Belt



1. Bolt

2. Deflector

3. Spring

Cone Locknut

Mount

Figure 56

7. Locknut

Pivot Bracket Carriage Bolt

m–2549

Page 62

Maintenance

Wiring

RADIATOR

TEMP SWITCH

white

blue

FAN

ALTERNATOR FUSE

Diagram

FAN RELAY

STARTER RELAY

12 GA.

white

red

12 GA.

red

12 GA.

red

yellow

orange

red

blue

red

brown

yellow

red

12 GA.

red

12 GA.

FAN FUSE

STARTER SOLENOID

POWER

red

blue

red

dark blue

white

orange

ENGINE CONNECTOR

white

ENGINE GROUND

white

red

yellow

red

white

green

light blue

RH MOTION CONTROL

green

white

brown

grey

yellow

orange

dark blue

orange

OPC RELAY

white

2.5

white

green

black

orange

grey

green

black

white

grey

brown

orange

light blue

grey grey

orange

white

blue white white

yellow orange

dark blue

green light blue light blue

green green green

black

orange

black

white

INTERLOCK MODULE

Page 63

iring Diagram

CLUTCH

orange

white

red

yellow

white

Maintenance

ALTERNATOR

Exciter

Positive

red

Negative

yellow orange

dark blue

green

light blue

green green green

black

orange

black

white

blue white white

SEAT SWITCH

grey grey

BATTERY

red

orange

white

FUEL PUMP

VOLTMETER

IGNITION SWITCH

white

white white

orange

black black

yellow

red

white

orange

blue

white

orange

light blue

orange

light blue

green

light blue

green

ENGINE

TEMP GAGE

CLUTCH SWITCH

BRAKE SWITCH

FUSE

red

HOURMETER

orange

dark blue

orange

green

LH MOTION

CONTROL

light blue

green

Page 64

Maintenance

Cleaning and Storage

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

parking brake and turn the ignition key to “OFF” to stop the engine. Remove 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. A use of water, especially near the control panel, engine, hydraulic pumps and motors.

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

page 36.

4. Grease and oil the machine; refer to Greasing

and Lubrication, page 44.

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

page NO TAG.

void excessive

11. For long-term storage (more than 90 days) add

stabilizer/conditioner additive to fuel in the tank (1 oz. per gallon).

A. Run engine to distribute conditioned fuel

through the fuel system (5 minutes).

B. Stop engine, allow to cool and drain the

fuel tank; refer to Fuel Tank, page 46.

C. Restart engine and run until it stops.

Repeat, on “CHOKE” until engine will not restart.

D. Dispose of fuel properly. Recycle as per

local codes.

Note: Do not store stabilizer/conditioned

gasoline over 90 days.

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

condition; refer to Spark Plug, page 43. 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).

6. Change the hydraulic fluid; refer to Hydraulic

System, page 47.

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

page 45.

8. Charge the battery; refer to Battery page 54.

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

Cutting Blades on page 33.

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 65

Troubleshooting

g,,

PROBLEM

Starter does not crank

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

POSSIBLE CAUSES

Blade control (PT ENGAGED.

Parking brake is not on.

Operator is not seated.

Battery is dead.

Electrical connections are corroded or loose.

Fuse is blown.

Relay or switch is defective.

Fuel tank is empty

Choke is not ON.

Air cleaner is dirty

Spark plug wires is loose or disconnected.

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

O) is

. 1.

. 3.

CORRECTIVE ACTION

Move blade control (PT DISENGAGED.

Set parking brake.

Sit on the seat.

Charge the battery

Check electrical connections for good contact.

Replace fuse.

Contact Authorized Service Dealer.

Fill fuel tank with gasoline.

Move choke lever to ON. Clean or replace air cleaner

element.

Install wires on spark plug.

Install new spark plugs.

, correctly gapped

O) to

Engine loses power

Dirt in fuel filter

Dirt, water fuel system.

Engine load is excessive.

Air cleaner is dirty

Oil level in crankcase is low

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

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

6. V

ent in fuel cap is closed.

Dirt in fuel filter

Dirt, water fuel system.

. 6.

, or stale fuel is in

. 2.

. 7.

, or stale fuel is in

. 3.

Replace fuel filter

Contact Authorized Service Dealer.

Reduce ground speed. Clean air cleaner element. Add oil to crankcase.

Remove obstruction from cooling fins and air passages.

Install new spark plugs.

Open vent in fuel cap. Replace fuel filter

Contact Authorized Service Dealer.

, correctly gapped

Page 66

Troubleshooting

PROBLEM

Engine overheats.

Machine does not drive.

Abnormal vibration.

POSSIBLE CAUSES

More coolant is needed.

(3) air intake screens are dirty.

Restricted air flow into the engine.

Radiator fins are dirty

The crankcase oil level is incorrect.

The fuel mixture is lean.

Excessive loading.

1. T

raction belt is worn, loose or

broken.

2. T

raction belt is of

Hydro fluid level low

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

f pulley

. 4.

. 2.

. 3.

CORRECTIVE ACTION

Check and add coolant. Clean with every use.

Inspect and clean the radiator screen with every use.

Clean the radiator fins. Fill or drain to the full mark.

Contact your Authorized Service Dealer

Reduce load; use lower ground speed.

Contact Authorized Service Dealer.

Add hydro fluid to reservoir Install new cutting blade(s).

Uneven cutting height.

Blade mounting bolt is loose.

Engine mounting bolts are loose.

Loose engine pulley pulley

, or blade pulley

Engine pulley is damaged.

Blade spindle bent.

Blade(s) not sharp.

Cutting blade(s) is/are bent.

Mower is not level.

Gage wheel not set correctly

Underside of mower is dirty

6. T

ire pressure is incorrect.

Blade spindle bent.

, idler

2. T

ighten blade mounting bolt.

3. T

ighten engine mounting

bolts.

4. T

ighten the appropriate

pulley.

Contact Authorized Service Dealer.

Sharpen blade(s).

Install new cutting blade(s).

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

Adjust gage wheel height.

Clean the underside of the mower.

Adjust tire pressure.

Contact Authorized Service Dealer.

Page 67

Troubleshooting

PROBLEM

Blades do not rotate.

POSSIBLE CAUSES

Drive belt is worn, loose or broken.

Drive belt is of

Deck belt is worn, loose or broken.

Deck belt is of

f pulley

. 2.

. 4.

CORRECTIVE ACTION

Install new drive belt.

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

Install new deck belt.

Install deck pulley and check the idler pulley spring for correct position and function.

, idler arm and

Page 68

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

Rev

9/30/98

ur-