Toro 74239, 74244 Operator's Manual

Download

Form No. 3351–973

Z500 and Z553

Z Master with 52in or 60in TURBO FORCE Side Discharge Mower

Model No. 74239–250000001 & Up Model No. 74244–250000001 & Up

Operator’s Manual

Original Instructions (EN)

Warning

CALIFORNIA

Proposition 65 Warning

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

Important This engine is not equipped with a spark

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

This spark ignition system complies with Canadian ICES-002.

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

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

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

Contents

Page

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

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

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

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

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

Gasoline and Oil 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 15. . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 15. . . . . . . . . . . . . . . .

Filling the Fuel Tank 15. . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 15. . . . . . . . . . . . . . . . . . . .

Operation 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Rollover Protection System (ROPS) 16. .

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

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

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

Operating in Cool Weather 19. . . . . . . . . . . . . . . . .

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

 2004 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

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

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

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

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

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

Using the Lift Assist Lever 22. . . . . . . . . . . . . . . . .

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

Adjusting the Flow Baffle 23. . . . . . . . . . . . . . . . . .

Positioning the Flow Baffle 23. . . . . . . . . . . . . . . . .

Positioning the Seat 24. . . . . . . . . . . . . . . . . . . . . . .

Unlatching the Seat 24. . . . . . . . . . . . . . . . . . . . . . .

Pushing the Machine by Hand 24. . . . . . . . . . . . . . .

Using the Side Discharge 25. . . . . . . . . . . . . . . . . . .

Breaking in a New Machine 25. . . . . . . . . . . . . . . .

Transporting Machines 25. . . . . . . . . . . . . . . . . . . .

Loading Machines 25. . . . . . . . . . . . . . . . . . . . . . . .

Tips for Mowing Grass 26. . . . . . . . . . . . . . . . . . . .

Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Maintenance Schedule 28. . . . . . . .

Servicing the Cutting Blades 29. . . . . . . . . . . . . . . .

Servicing the Air Cleaner 31. . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 32. . . . . . . . . . . . . . . . . . .

Servicing the Spark Plug 33. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 34. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Tank 34. . . . . . . . . . . . . . . . . . . .

Greasing and Lubrication 35. . . . . . . . . . . . . . . . . . .

Greasing the Spindles 36. . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling Systems 36. . . . . . . . . . . . . . .

Checking the Tire Pressure 37. . . . . . . . . . . . . . . . .

Checking the Wheel Hub Slotted Nut 37. . . . . . . . .

Adjusting the Caster Pivot Bearing 37. . . . . . . . . . .

Servicing the Hydraulic System 38. . . . . . . . . . . . .

Adjusting the Handle Neutral 40. . . . . . . . . . . . . . .

Setting the Hydraulic Pump Neutral 40. . . . . . . . . .

Adjusting the Tracking 41. . . . . . . . . . . . . . . . . . . .

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

Adjusting the Parking Brake 42. . . . . . . . . . . . . . . .

Servicing the Fuse 43. . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 43. . . . . . . . . . . . . . . . . . . . . .

Leveling the Mower at Three Positions 45. . . . . . . .

Cleaning Under the Mower 47. . . . . . . . . . . . . . . . .

Inspecting the Belts 47. . . . . . . . . . . . . . . . . . . . . . .

Replacing the Mower Belt 47. . . . . . . . . . . . . . . . . .

Adjusting the Mower Belt Tension 48. . . . . . . . . . .

Replacing the Grass Deflector 49. . . . . . . . . . . . . . .

Wiring Diagram 51. . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 52. . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Toro Total Coverage Guarantee 56. . . . . . . . . . . . .

Printed in the USA

Page

Introduction

Safety

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

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

Figure 1

1. Location o f the model and serial numbers

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

Model No.

Serial No.

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

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

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

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

Safe Operating Practices

The following instructions are from ANSI standard B71.4—2004.

Training

• Read the Operator ’s Manual and other training

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

• Become familiar with the safe operation of the

equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The

owner is responsible for training the users.

• Never let children or untrained people operate or

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

• The owner/user can prevent and is responsible for

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

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

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

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

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

Preparation

• Evaluate the terrain to determine what accessories and

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

• Wear appropriate clothing including hard hat, safety

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

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

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

• Use extra care when handling gasoline and other fuels.

They are flammable and vapors are explosive.

• Use extreme care when loading or unloading the

machine into a trailer or truck.

• Use only an approved container

• Never remove gas cap or add fuel with engine

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

• Never refuel or drain the machine indoors.

• Check that operator ’s presence controls, safety

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

Operation

• Never run an engine in an enclosed area.

• Only operate in good light, keeping away from holes

and hidden hazards.

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

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

• Never raise mower with the blades running.

• Never operate without the PTO shield, or other guards

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

• Never operate with the discharge deflector raised,

removed or altered, unless using a grass catcher.

• Do not change the engine governor setting or

overspeed the engine.

• Stop on level ground, lower implements, disengage

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

• Stop equipment and inspect blades after striking

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

• Use care when approaching blind corners, shrubs,

trees, or other objects that may obscure vision.

Slope Operation

• Do not mow slopes greater than 15 degrees.

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

water. Wheels dropping over edges can cause

rollovers, which may result in serious injury, death or

drowning.

• Do not mow slopes when grass is wet. Slippery

conditions reduce traction and could cause sliding and

loss of control.

• Do not make sudden turns or rapid speed changes.

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

drop–offs, ditches, steep banks or water.

• Reduce speed and use extreme caution on slopes.

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

etc. from the mowing area. Tall grass can hide

obstacles.

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

change the operating angle, as rough terrain could

overturn the machine.

• Avoid sudden starts when mowing uphill because the

mower may tip backwards.

• Be aware that loss of traction may occur going

downhill. Weight transfer to the front wheels may

cause drive wheels to slip and cause loss of braking

and steering.

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

tires lose traction, disengage the blades and proceed

slowly off the slope.

• Follow the manufacturer ’s recommendations for wheel

weights or counterweights to improve stability.

• Keep hands and feet away from the cutting units.

• Never carry passengers and keep pets and bystanders

away.

• Be alert, slow down and use caution when making

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

• Slow down and use caution when crossing roads and

sidewalks. Stop blades if not mowing.

• Be aware of the mower discharge direction and do not

point it at anyone.

• Do not operate the mower under the influence of

alcohol or drugs.

• Use extreme care with grass catchers or other

attachments. These can change the stability of the

machine and cause loss of control.

Using the Rollover Protection System (ROPS)

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

use the seat belt when operating the machine.

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

the event of an emergency.

• Be aware there is no rollover protection when the roll

bar is down.

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

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

• Lower the rollbar only when absolutely necessary. Do

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

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

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

Maintenance and storage

• Disengage drives, lower implement, set parking brake,

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

• Clean grass and debris from cutting units, drives,

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

• Let engine cool before storing and do not store near

flame.

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

fuel near flames or drain indoors.

• Park machine on level ground. Never allow untrained

personnel to service machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with

stored energy.

• Disconnect battery or remove spark plug wire before

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

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

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

• Keep hands and feet away from moving parts. If

possible, do not make adjustments with the engine running.

• Charge batteries in an open well ventilated area, away

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

• Keep all parts in good working condition and all

hardware tightened. Replace all worn or damaged decals.

• Use only Toro-approved attachments. Warranty may

be voided if used with unapproved attachments.

Slope Chart

Example: Compare

slope with folded

edge.

Fold along appropriate line

Align this edge with a vertical surface (Tree, Building, Fence post, pole, etc.)

Safety and Instruction Decals

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

1-633462

1-643339

54-9220

1-523552

43-8480

58-6520

1. Grease

66-1340

68-8340

98-4387

1. Warning—wear hearing protection.

98-5954

103-5881

105-7797

105-7798

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

104-8569

Manual.

Operator’s

distance from the battery.

106-9969

107-1613

107-1864

107-1622

107-2102

107-1621

107-2112

107-1860

107-1857

107-1861

107-8076

106-9989

106-7492

1. Contains lead; do not discard.

2. Recycle

104-4164

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

4. No sparks, flame, or smoking

5. Sulfuric acid can cause blindness or severe burns.

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

7. Maximum fill line

8. Minimum fill line

9. Instructions for activating the battery

Gasoline and Oil

Warning

Recommended Gasoline

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

Important Never use methanol, gasoline containing

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

Danger

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

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

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

• Never fill the fuel tank inside an enclosed

trailer.

• Do not fill the fuel tank completely full. Add

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

• Never smoke when handling gasoline, and stay

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

• Store gasoline in an approved container and

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

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle

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

• When practical, remove gas–powered

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

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used,

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

• Do not operate without entire exhaust system in

place and in proper working condition.

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

• Avoid prolonged breathing of vapors.

• Keep face away from nozzle and gas tank or

conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

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

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

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel

system, which causes hard starting

Important Do not use fuel additives containing

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

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

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

Filling the Fuel Tank

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

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

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

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

that may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 32.

Operation

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

Using the Rollover Protection

System (ROPS)

Warning

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

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

Warning

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

• Lower the roll bar only when absolutely

necessary.

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

the down position.

• Drive slowly and carefully.

• Raise the roll bar as soon as clearance permits.

• Check carefully for overhead clearances (i.e.

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

m–7447

Figure 2

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

Important Always use the seat belt with the roll bar in

the raised position.

Important Ensure that the rear part of the seat is

secured with the seat latch.

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

remove the two pins (Fig. 3).

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

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

Important Lower the roll bar only when absolutely

necessary.

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

2. Remove the hairpin cotter pins and remove the two

pins (Fig. 3).

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

two down positions. See Figure 2 for the positions.

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

cotter pins (Fig. 3).

1. Roll bar

2. Raised position

m–7431

Figure 3

3. Pin

4. Hairpin cotter pin

7. Tighten the front handles against the center roll bar

ends (Fig. 3).

m–6897

Figure 4

1. Front handle

Think Safety First

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

Danger

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

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

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

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

Read and follow the rollover protection instructions and warnings.

To avoid loss of control and possibility of rollover:

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

• Do not operate on slopes greater than

15 degrees.

• Reduce speed and use extreme caution on

slopes.

• Avoid sudden turns or rapid speed changes.

m–6478

Figure 5

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

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

3. Water

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

Caution

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

Wear hearing protection when operating this machine.

Figure 6

1. Warning—wear hearing protection.

Controls

Operating the Parking Brake

Become familiar with all the controls (Fig. 7 and 8) before you start the engine and operate the machine.

m–6834

Figure 7

1. Motion control lever

2. Parking brake lever

3. Height-of-cut lever

4. Fuel cap (both sides)

5. Lift assist lever

6. Controls

7. Seat belt

8. Roll bar

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. 7) out to the

neutral lock position.

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

parking brake (Fig. 9). The parking brake lever should stay firmly in the engaged position.

Warning

Parking brake may not hold machine parked on a slope and could cause personal injury or property damage.

Do not park on slopes unless wheels are chocked or blocked

Releasing the Parking Brake

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

release the parking brake (Fig. 9). The parking brake is disengaged and the lever will rest against the brake stop.

1 4

m–6838

Figure 8

1. Ignition switch

2. Throttle

3. Choke

4. Power take off (PTO)

5. Hour meter

6. Gas cap

Using the Hour Meter

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

Unlatch the seat and lift it up to view the hour meter (Fig. 8).

1. Parking brake-ON

2. Parking brake-OFF

m–4163

Figure 9

3. Brake Stop

Operating in Cool Weather

The engine on this machine may take 5 to15 minutes to reach full operating temperature in cool weather conditions.

Keep the choke applied slightly to keep the engine running smoothly from cold startup or when engaging the mower deck.

Starting and Stopping the Engine

Starting the Engine

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 18.

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

position (Fig. 10).

4. Move the choke control to the on position before

starting a cold engine.

Note: A warm or hot engine may not require choking. After engine starts, move choke control to run position.

Figure 10

1. PTO-On

2. PTO-Off

m–4201

m–2719

Figure 11

1. Choke–On

2. Choke–Off

5. Move the throttle control to the fast position before

starting a cold engine.

6. Turn the ignition key to start. When the engines starts,

release the key.

Important Do not engage starter for more than

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

7. After the engine starts, move the choke to off (Fig. 11).

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.

M–4268

Figure 12

1. Throttle–Fast

2. Throttle–Slow

m–2720

Figure 13

1. Off

2. Run

3. Start

Stopping the Engine

1. Push the PTO to the off position (Fig. 12).

2. Move the throttle lever midway between the slow and

fast positions (Fig. 12).

3. Let the engine idle for 60 seconds (Fig. 13).

4. Turn the ignition key to the off position and remove

the key (Fig. 13).

5. Close the fuel shut off valve before transporting or

storing the machine.

Important Make sure that the fuel shut off valve is

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

Caution

The Safety Interlock System

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

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

Operating the Power Take Off (PTO)

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

Engaging the PTO

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

traction control levers and place in neutral.

2. Place the throttle to the fast position.

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

(Fig. 14).

Caution

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

• You are sitting on the seat.

• The parking brake is engaged.

• The power take off (PTO) is disengaged.

• The motion control levers are in neutral locked

position.

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

Figure 14

1. PTO—Off 2. PTO—On

Disengaging the PTO

To disengage, push the PTO switch to the off position (Fig. 14).

m–4201

Testing the Safety Interlock System

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

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

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

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

the PTO to 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 the parking brake, move the

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

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

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

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

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

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

To turn, move the motion control lever toward neutral in the direction you want to turn (Fig. 15).

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 the neutral position.

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.

Caution

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

• Use caution when making turns.

• Slow the machine down before making sharp

turns.

Driving Forward

1. Release the parking brake; refer to Releasing the

Parking Brake, page 18.

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

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

forward (Fig. 15).

Driving Backward

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

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

rearward (Fig. 15).

To go straight, apply equal pressure to both motion control levers (Fig. 15).

To turn, release pressure on the motion control lever toward the direction you want to turn (Fig. 15).

To stop push the motion control levers to the neutral position.

Stopping the Machine

To stop the machine, move the traction control levers to neutral and move to locked position, disengage the power take off (PTO), and turn the ignition key to off. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 18. Remember to remove the key from the ignition switch.

Caution

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

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

m–2715

Figure 15

1. Motion control lever-neutral lock position

2. Center un-lock position

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

To go straight, apply equal pressure to both motion control levers (Fig. 15).

3. Forward

4. Backward

Adjusting the Height-of-Cut

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

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

(also the 5 inch (127 mm) cutting height position) (Fig. 16).

2. To adjust, remove the clevis pin from the height-of-cut

bracket (Fig. 16).

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

the height-of-cut desired and, insert the clevis pin (Fig. 16).

2. After adjusting the height-of-cut, adjust the rollers by

removing the flange nut, bushing, spacer, and bolt (Fig. 18).

4. Move the lever to the selected height.

m–6820

Figure 16

1. Height of cut lever 2. Clevis Pin

Using the Lift Assist Lever

The lift assist lever is used along with the height–of–cut lever for raising the mower. This allows for easier raising of the mower.

1. Place your foot onto lift assist lever.

2. Press on the lift assist lever while pulling up on the

height–of–cut lever (Fig. 17).

Note: The two middle rollers will not have a spacer (Fig. 19).

3. Select a hole so the anti–scalp roller is positioned to

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

4. Install the flange nut, bushing, spacer, and bolt. Torque

to 40–45 ft–lb (54–61 N⋅m) (Fig. 18).

5. Repeat this adjustment on the other anti–scalp rollers.

m–6821

Figure 18

1. Anti–scalp roller

2. Spacer

3. Bushing

4. Flange Nut

5. Bolt

m–5028

Figure 17

1. Lift Assist Lever

Adjusting the Anti-Scalp Rollers

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

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

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

1. Anti–scalp roller

2. Bushing

m–6845

Figure 19

3. Flange Nut

4. Bolt

Positioning the Flow Baffle

The following figures are only recommendations for use. Adjustments will vary by grass type, moisture content, and height of grass.

m–6844

Figure 20

1. Anti–scalp roller

2. Spacer

3. Bushing

4. Flange Nut

5. Bolt

Adjusting the Flow Baffle

The mower discharge flow can be adjusted for different types of mowing conditions. Position the cam locks and baffle to give the best quality of cut.

1. To adjust the cam locks, swing the lever up to loosen the cam lock (Fig. 25).

2. Adjust the baffle and cam locks in the slots to the desired discharge flow.

Note: If the engine power draws down and the mower ground speed is the same, open up the baffle.

Position A

This is the full rear position. The suggested use for this position is a follows.

• Use for short, light grass mowing conditions.

• Use in dry conditions.

• For smaller grass clippings.

• Propels grass clippings farther away from the mower.

Full Rearward Position

m–6829

Figure 22

3. Swing the lever back over to tighten the baffle and cam locks.

4. If the cams do not lock the baffle into place or it is too tight, loosen the lever and then rotate the cam lock. Adjust the cam lock until the desired locking pressure is achieved.

m–6823

Figure 21

1. Cam lock

2. Lever

3. Rotate cam to increase or decrease locking pressure

4. Slot

Position B

Use this position when bagging.

Middle Position

m–6828

Figure 23

Position C

This is the full open position. The suggested use for this position is as follows.

• Use in tall, dense grass mowing conditions.

• Use in wet conditions.

Unlatching the Seat

Push the seat latch rearward to unlatch the seat. This will allow access to the machine under the seat.

• Lowers the engine power consumption.

• Allows increased ground speed in heavy conditions.

• This position is similar to the benefits of the Toro SFS

mower.

Full Forward Position

m–6827

Figure 24

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 the seat

(Fig. 25).

m–6840

Figure 26

1. Seat latch

2. Gas cap

3. Seat

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

Pushing the Machine

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

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

2. Raise the seat.

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

lever to lock it in position.

m–3655

Figure 25

1. Adjustment lever

3. 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. 27).

Important Do not rotate by-pass valves more than

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

4. Disengage the parking brake before pushing.

Changing to Machine Operation

Rotate the by-pass valves clockwise 1 turn to operate machine (Fig. 27).

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

valves are turned in.

Figure 27

1. By-pass valve 2. Hydraulic tank

Using the Side Discharge

Breaking in a New Machine

New engines take time to develop full power. Mower decks and drive systems have higher friction when new, placing additional load on the engine. Allow 40 to 50 hours of break–in time for new machines to develop full power for best performance.

Transporting Machines

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

To transport the machine:

• Lock the brake and block the wheels.

• Securely fasten the machine to the trailer or truck with

straps, chains, cable, or ropes.

• Do not use the motion control levers as anchors for

tieing the machine down.

• Secure a trailer to the towing vehicle with safety

chains.

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

Danger

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

• Never remove the grass deflector from the

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

• Never put your hands or feet under the mower.

• Never try to clear the discharge area or mower

blades unless you move the power take off (PTO) to the off position, rotate the ignition key to off and remove the key.

• Make sure the grass deflector is in the

down position.

Warning

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

Do not drive machine on a public street or roadway.

Loading Machines

Use extreme caution when loading units on trailers or trucks. One full width ramp that is wide enough to extend beyond the rear tires is recommended instead of individual ramps for each side of the unit (Fig. 28). The lower rear section of the tractor frame extends back between the rear wheels and serves as a stop for tipping backward. Having a full width ramp provides a surface for the frame members to contact if the unit starts to tip backward. If it is not possible to use one full width ramp, use enough individual ramps to simulate a full width continuous ramp.

The ramp should be long enough so that the angles do not exceed 15 degrees (Fig. 28). A steeper angle may cause mower mower components to get caught as the unit moves from ramp to trailer or truck. Steeper angles may also cause the unit to tip backward. If loading on or near a slope, position the trailer or truck so it is on the down side

of the slope and the ramp extends up the slope. This will minimize the ramp angle. The trailer or truck should be as level as possible.

Important Do Not attempt to turn the unit while on

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

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

Warning

Tips for Mowing Grass

Fast Throttle Setting

For best mowing and maximum air circulation, operate the engine at the fast throttle position. 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.

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

• Use extreme caution when operating a unit on a

ramp.

• Use only a single, full width ramp; Do Not use

individual ramps for each side of the unit.

• If individual ramps must be used, use enough

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

• Do not exceed a 15 degree angle between ramp

and ground or between ramp and trailer or truck.

• Avoid sudden acceleration while driving unit up

a ramp to avoid tipping backward.

• Avoid sudden deceleration while backing unit

down a ramp to avoid tipping backward.

Cutting a Lawn for the First Time

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

Cut 1/3 of the Grass Blade

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

Mowing Direction

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

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.

m–6841

1. Trailer

2. Full width ramp

3. Not greater than 15 degrees

Figure 28

4. Full width ramp—side view

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

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

Keep the Underside of the Mower Clean

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

Blade Maintenance

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

Maintenance

Recommended Maintenance Schedule

Maintenance Service

Interval

After first 5 hours

Each Use

Every 8 Hours • Cutting Blades—check

Every 25 Hours

Every 50 Hours

Every 100 Hours

Every 200 Hours

Every 250 Hours

• Hydraulic fluid—check level

• Hydraulic filter—change

• Oil—check level

• Safety System—check

• Mower Housing—clean

• Engine air intake—clean

• Idler arm—grease

• Traction belt idler arm—grease

• Brake lever—grease

• Mower support arms—grease

• Linkage bushings—oil

• Hydraulic fluid—check level

• Battery—check electrolyte

• Blade Spindle Bearings—grease

• Belts—adjust tension

• Belts—check for wear/cracks

• Tires—check pressure

• Engine Oil—change

• Hydraulic lines—check

• Engine Cooling System—clean

• Oil Filter—change (200 hours or every other oil change)

• Hydraulic filter—change

• Spark Plug(s)—check

• Fuel Filter—replace

• Brake pivot—grease

• Replace primary air cleaner filter

• Safety air cleaner1— check

Maintenance Procedure

Every 500 Hours or at

Storage

Every 600 Hours or at

Storage

Before Storage Service

More often in dusty, dirty conditions

• Caster Pivot— adjustment

• Wheel Hub Slotted Nut— adjustment

• Safety air cleaner1— replace

• Battery–charge, Disconnect cables

• Gasoline—drain

• Chipped Surfaces—paint

• Perform all maintenance procedures listed above before storage

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

Caution

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

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

Servicing the Cutting Blades

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

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

Danger

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

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

Before Inspecting or Servicing the Blades

Inspecting the Blades

1. Inspect the cutting edges (Fig 29). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 30.

2. Inspect the blades, especially the curved area (Fig. 29).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 29), immediately install a new blade.

m–151

1. Cutting Edge

2. Curved Area

Figure 29

3. Wear/slot Forming

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

Checking for Bent Blades

Removing the Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 30). Measure from a level surface to the cutting edge, position A, of the blades (Fig. 31). Note this dimension.

F ront

Figure 30

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

Figure 31

m–1078

m–2539

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

Warning

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

with a rag.

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. 34).

Sharpening the Blades

Warning

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

Wear proper eye protection when sharpening blade.

2. Rotate the opposite ends of the blades forward.

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

blades at the same position as in step 1. The difference between the dimensions obtained in steps 1 and 2 must not exceed 1/8 inch (3 mm). If this dimension exceeds 1/8 inch (3 mm), the blade is bent and must be replaced. Refer to Removing the Blades and Installing the Blades.

Warning

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

• Always replace bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of blade.

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

the blade (Fig. 32). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

m–1854

Figure 32

1. Sharpen a t original angle

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

balancer (Fig. 33). 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. 34). Repeat this procedure until the blade is balanced.

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

cleaner cover off of the air cleaner body (Fig. 35).

4. Clean the inside of the air cleaner cover with

compressed air.

m–1855

Figure 33

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft (Fig. 34).

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 (Fig. 34). Torque the blade bolt to 85–110 ft-lb (115–150 N m).

3 5

1. Sail Area of Blade

2. Blade

3. Spring Disk

Figure 34

4. Blade Bolt

5. Cone T owards Bolt Head

M–4226

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

body (Fig. 35). Avoid knocking the filter into the side of the body.

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

Important Never attempt to clean the safety filter. If

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

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

m–4815

Figure 35

1. Latches

2. Air cleaner cover

3. Air filter body

4. Primary filter

5. Safety filter

Servicing the Air Cleaner

Primary Filter: Replace after every 250 operating hours. Safety Filter: Replace after every 600 operating hours. Note: Check the filters more frequently if operating

conditions are extremely dusty or sandy.

Removing the Filters

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

Servicing the Primary Filter

Do not clean the primary filter. Replace it after 250 operating hours.

Servicing the Safety Filter

Do not clean the safety filter. Replace it after 600 operating hours.

Important Never attempt to clean the safety filter. If

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

Installing the Filters

Important To prevent engine damage, always operate

the engine with both air filters and cover installed.

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

damage. Do not use a damaged filter.

3. Clean around the oil dipstick (Fig. 36) so dirt cannot

fall into the filler hole and damage the engine.

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

into the filter body (Fig. 35).

3. Carefully slide the primary filter over the safety filter

(Fig. 35). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

Important Do not press on the soft inside area of the

filter.

4. Install the air cleaner cover with the side indicated as UP facing up and secure the latches (Fig. 35).

Servicing the Engine Oil

Change oil:

• After every 100 operating hours.

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

Oil Type: Detergent oil (API service SH, SJ, SL or higher) Crankcase Capacity: w/filter, 67 oz. (2.0 l) Viscosity: See table below

USE THESE SAE VISCOSITY OILS

4. Pull the oil dipstick and wipe the metal end clean

(Fig. 36).

5. Slide the oil dipstick fully into the filler tube. Pull the

dipstick out and look at the metal end (Fig. 36). 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 this may cause engine damage. Do not run the engine with oil below the low mark because the engine may be damaged as a result.

1. Oil dipstick

2. Filler tube

Figure 36

3. Metal end

m–3219m–4811

10W–30

5W–20, 5W–30

–20 0 20

°F

–30 –20 –10

°C

40 60

01020

80 100

30 40

Checking the Oil Level

Note: Check the oil when the engine is cold.

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

the neutral locked position and set the parking brake.

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

Changing the Oil

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

the oil so it drains better.

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

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

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

valve to allow oil to drain (Fig. 37).

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

valve.

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

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. 38).

m–5624

Figure 37

1. Oil drain valve

5. Slowly pour approximately 80% of the specified oil

into the filler cap (Fig. 36). Refer to Servicing the Engine Oil, page 32.

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

page 32.

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

Change the Oil Filter

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

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

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

Oil, page 32.

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

refer to Changing the Oil, page 32.

Servicing the Spark Plug

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

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

Removing the Spark Plug(s)

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Pull the wire(s) off the spark plug(s) (Fig. 39). Now

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

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

2. Remove the old filter and wipe the filter adapter

(Fig. 38) 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. 38).

m–1256

Figure 38

1. Oil filter

2. Gasket

3. Adapter

m–4811

Figure 39

1. Spark plug wire 2. Spark plug

Checking the Spark Plug

1. Look at the center of the spark plug(s) (Fig. 40). If you

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

Important Never clean the spark plug(s). Always

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

2. Check the gap between the center and side electrodes (Fig. 40). Bend the side electrode (Fig. 40) if the gap is not correct.

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

the filter (Fig. 42).

8. Wipe up any spilled fuel.

9. Open fuel shut-off valve (Fig. 41).

0.030 inch (0.76 mm)

m–3215

Figure 40

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

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

correctly.

2. Tighten the spark plug(s) to 20 ft-lb (27 N⋅m).

3. Push the wire(s) onto the spark plug(s) (Fig. 39).

Servicing the Fuel Filter

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

2 1 2

Figure 41

1. Filter

2. Hose clamp

3. Fuel shut-off valve

Servicing the Fuel Tank

Draining The Fuel Tank

Danger

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

m–6842

Replacing the Fuel Filter

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

1. Allow the machine to cool down.

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

4. Close the fuel shut–off valve (Fig. 41).

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

them away from the filter (Fig. 41).

6. Remove the filter from the fuel lines.

• Drain gasoline from the fuel tank when the

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

• Never smoke when draining gasoline, and stay

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

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

tank drains completely. Then disengage the power take off (PTO), set the parking brake, and turn the ignition key to off. Remove the key.

2. Close the fuel shut–off valve (Fig. 42).

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

the fuel line away from the fuel filter (Fig. 42).

4. Pull the fuel line off fuel filter (Fig. 42). 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.

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

hole.

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

clamp close to the fuel filter to secure the fuel line (Fig. 42).

1 23

m–6842

Figure 42

1. Fuel shut-off valve

2. Fuel filter

3. Hose clamp

4. Fuel line

Greasing and Lubrication

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

top bearing.

4. Remove the grease zerk in the hole. Install the hex

plug and cap.

Where to Add Grease

Lubricate the grease fittings as shown on the Check Service Reference Aid decal (Fig. 43).

Lubricate the machine when shown on the Check Service Reference Aid decal (Fig. 43). Grease more frequently

when operating conditions are extremely dusty or sandy. Grease Type: General-purpose grease.

How to Grease

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

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

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

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

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

5. Wipe up any excess grease.

Greasing the Front Caster Pivots

Lubricate the front caster pivots once a year.

Figure 43

Where to Add Light Oil or Spray Lubrication

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

• Seat switch actuator.

• Brake handle pivot.

• Brake rod bushings.

• Motion control bronze bushings.

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

the dust cap off until greasing is done. Refer to Adjusting the Caster Pivot Bearing, page 37.

Greasing the Spindles

The cutting unit must be lubricated weekly or every 25 hours. Refer to the Service Interval Chart on page 28. Grease with No. 2 general purpose lithium base or molybdenum base grease.

Important Make sure cutting unit spindles are full of

grease weekly.

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Grease the three spindle bearings under the pulleys

until grease comes out the lower seals (Fig. 44).

4. Grease the fittings on the push arms (Fig. 44).

Cleaning the Cooling Systems

Cleaning the Engine Screen and the Oil Cooler

Before each use, check and clean engine screen and oil cooler. Remove any build–up of grass, dirt or other debris from the oil cooler and engine air intake screen (Fig. 45).

m–3801

Figure 45

1. Engine screen 2. Oil cooler

Cleaning the Engine Fins

Every 100 hours clean engine cylinder and cylinder head cooling fins. Also clean around carburetor, governor levers and linkage. This will make sure adequate cooling to hydraulic pumps, motors and engine and will reduce the possibility of overheating and mechanical damage.

m–6822

Figure 44

1. Remove the panels from the engine shroud.

2. Clean the engine cooling fins.

3. Install the panels onto the engine shroud.

Figure 46

1. Panel

2. Engine shroud

3. Screws

m–5616

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 47). Check the tires when they are cold to get the most accurate pressure reading.

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

edge of hole. Two threads or less should be showing (Fig. 48).

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

install washer between hub and nut (Fig. 48).

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

(Fig. 48).

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

m–1872

Figure 47

1. Valve stem

Checking the Wheel Hub Slotted Nut

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

(170 N⋅m).

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

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

hole in the shaft (Fig. 48).

9. Replace cotter pin.

Adjusting the Caster Pivot Bearing

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

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Remove dust cap from caster and tighten lock nut

(Fig. 49).

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

a 1/4 turn to properly set the pre–load on the bearings (Fig. 49).

Important Make sure spring washers are installed

correctly as shown in figure 49.

5. Install the dust cap (Fig. 49).

3. Remove the cotter pin.

4. Torque the slotted nut to 125 ft–lb (170 N⋅m) (Fig. 48).

m–4638

Figure 48

1. Slotted Nu t

2. Two threads or less showing

3. Hole in threaded rod

4. Washer (if needed)

1. Spring Washers

2. Lock Nut

2 1

M–4640

Figure 49

3. Dust Cap

Servicing the Hydraulic System

Checking the Hydraulic Fluid

Check the hydraulic fluid level:

• Before the engine is first started.

• After the first 8 operating hours.

• After every 25 operating hours.

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

Important Use oil specified or equivalent. Other

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

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

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

parking brake.

2. Clean the area around filler neck of hydraulic tank

(Fig. 50).

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

check if there is fluid in the reservoir (Fig. 50).

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

5. Run the machine at low idle for 15 minutes to allow any air to purge out of the system and warm the fluid. Refer to Starting and Stopping the Engine on page 19.

6. Recheck the fluid level while the fluid is warm. If required, add fluid to the reservoir until it reaches the hot level of the baffle.

Note: The fluid level should be to the top of the hot level of the baffle, when the fluid is hot (Fig. 50).

7. Install cap on filler neck.

Figure 50

1. Cap

2. Baffle

3. Cold fluid level—full

4. Hot fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 8 operating hours.

m–5615

• After every 200 operating hours.

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

Important Do not substitute automotive oil filter or

severe hydraulic system damage may result.

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

wipe the filter adapter gasket surface clean (Fig. 51).

Bleeding the Hydraulic System

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

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

and support with jack stands.

M–4763

Figure 51

1. Hydraulic filter

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

on the replacement filter (Fig. 52).

5. Install the replacement hydraulic filter onto the filter

adapter. Do not tighten.

6. Fill the hydraulic tank with hydraulic fluid until the

fluid overflows the filter.

7. When fluid overflows the filter turn the hydraulic oil

filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 52).

8. Clean up any spilled fluid.

9. Add fluid to the cold level of the baffle in the

hydraulic tank, refer to Checking the Hydraulic Fluid on page 38.

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

purge air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 39.

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

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

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

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

engaged until wheel drives smoothly. (minimum 2 minutes)

4. Check hydraulic fluid level and add as required to

maintain proper level.

5. Repeat this procedure on the opposite wheel.

Checking the Hydraulic Lines

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

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

Warning

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

• If hydraulic fluid is injected into the skin it

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines

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

1. Hydraulic filter

2. Gasket

m–1256

Figure 52

3. Adapter

Adjusting the Handle Neutral

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

Note: The motion control levers must be installed correctly. See Installing the Motion Control Levers in the set up instructions.

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Unlatch the seat and tilt the seat forward.

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

5. Move the lever to the neutral position but not locked

(Fig. 54).

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

shaft) contacts the end of the slot (just beginning to put pressure on the spring) (Fig. 54).

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

console (Fig. 53). It should be centered allowing lever to pivot outward to the neutral lock position.

1011

Figure 54

1. Clevis pin in slot

2. Nut against yoke

3. Adjustment bolt

4. Pump rod

5. Double nuts

6. Jam Nut

7. Spring

8. Pivot shaft

9. Yoke

10. Locknut

11. Ball joint

Setting the Hydraulic Pump

M–6278

m–6282

Figure 53

1. Neutral locked position

2. Control lever

3. Neutral position

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

against the yoke (Fig. 54).

9. Apply slight rearward pressure on the motion control

lever, turn the head of the adjustment bolt in the appropriate direction until the control lever is centered in neutral lock position (Fig. 53).

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

Neutral

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

Danger

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

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Warning

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

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

10.Tighten the nut and jam nut (Fig. 54).

11. Repeat on the opposite side of the machine.

This adjustment must be made with the drive wheels turning.

1. Raise the frame and use jack stands to hold up the machine so drive wheels can rotate freely.

2. Unlatch the seat, tilt the seat forward and disconnect electrical connector from the seat safety switch.

3. Temporarily install a jumper wire across terminals in the wiring harness connector.

4. Slide the seat forward, disconnect the prop rod and tilt the seat fully forward.

Setting the Right–hand Hydraulic Pump Neutral

Setting the Left–hand Hydraulic Pump Neutral

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

rod (Fig. 54).

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

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

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

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

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

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

2. Adjust the pump rod length by rotating the knob, in the appropriate direction, until the wheel is still or slightly creeping in reverse (Fig. 55).

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

4. Open the throttle to fast. Make sure the wheel remains stopped or slightly creeps in reverse, adjust if necessary.

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

rod, in the appropriate direction, until wheel is still or slightly creeps in reverse (Fig. 54).

4. Move the motion control lever forward and reverse,

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

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

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

6. Tighten the locknuts at the ball joints (Fig. 54).

Warning

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

• Remove jumper wire from wire harness

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

• Never operate this unit with jumper installed

and seat switch bypassed.

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

1. Tracking knob

2. Pump rod

Figure 55

3. Adjustment bolt

4. Yoke

8. Remove the jumper wire from the wire harness

connector and plug the connector into the seat switch.

9. Install the seat rod and lower the seat into position.

10.Remove the jack stands.

m–6281

Adjusting the Tracking

The right hand pump has a knob for adjusting the tracking.

Important Adjust the handle neutral and hydraulic

pump neutral before adjusting the tracking. Refer to Adjusting the Handle Neutral on page 40 and Adjusting the Hydraulic Pump Neutral on page 40.

1. Push both control levers forward the same distance.

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

the machine and set the parking brake.

2. Install new belt around engine and hydro pump pulleys

(Fig. 57).

3. Unlatch the seat and tip the seat up to access the

tracking knob.

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

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

the rightside of the machine. Refer to figure 56.

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

the leftside of the machine. Refer to figure 56.

6. Repeat this adjustment until the tracking is correct.

m–6280

Figure 56

1. Pump rod

2. Turn this way to track left

3. Tracking knob

4. Turn this way to track right

3. Pull spring loaded idler down and align below traction

belt. Release pressure on spring loaded idler (Fig. 57).

Adjusting the Parking Brake

Check parking brake for proper adjustment.

1. Disengage brake lever (lever down).

2. Measure the length of the spring. Measurement should

be 2-3/4 inch (70 mm) between washers (Fig. 58).

Figure 58

1. Brake lever

2. Spring 2.75 inch (70 mm)

3. Adjusting nuts

4. Collar on brake rod

5. 3/16–1/4 inch (5–7 mm)

6. Jam nut and yoke

m–3788

Replacing the Pump Drive Belt

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

1. Pull the spring loaded idler down and remove traction

belt from the engine and hydro pump pulleys (Fig. 57). Remove belt between pulleys.

Figure 57

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

the spring and tighten the nut directly below the yoke (Fig. 58). 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.

A. Measure the distance between the trunnion roller

and the collar on brake rod. The measurement should be 3/16–1/4 inch (5–7 mm) (Fig. 58).

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

below the yoke. Turn the bottom rod until the correct measurement is obtained (Fig. 58). Tighten jam nut at yoke

Servicing the Fuse

Service Interval/Specification

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

Fuse: Main F1–30 amp, blade-type

Alternator F2–25 amp, blade-type

1. Unlatch the seat and raise the seat to gain access to fuse holder (Fig. 59).

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

3. Install a new fuse (Fig. 59).

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

distilled water; refer to Adding Water to the Battery, page 44.

1 2

Figure 60

1. Filler caps

2. Upper line

3. Lower line

Danger

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

m–5004

m–3653

Figure 59

1. Main-30 amp 2. Alternator-25 amp

Servicing the Battery

Warning

CALIFORNIA

Proposition 65 Warning

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

handling.

Checking Electrolyte Level

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

2. Look at the side of the battery. The electrolyte must be up to the upper line (Fig. 60). Do not allow the electrolyte to get below the lower line (Fig. 60).

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

Installing the Battery

1. Position battery in tray with terminal posts toward the

engine (Fig. 61).

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

(+) battery terminal.

3. Then install the negative battery cable and ground wire

to the negative (–) battery terminal.

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

2 washers (1/4 inch), and 2 locknuts (1/4 inch) (Fig. 61).

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

battery post.

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

2 washers (1/4 inch), and 2 wing nuts (1/4 inch) (Fig. 61).

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

the neutral locked position and set the parking brake.

m–5598

Figure 61

1. Battery

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

5. Ground wire

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

Removing the Battery

Warning

7. Washer, 1/4 inch

8. Locknut, 1/4 inch

9. Battery clamp

10. J-bolts

11. Wing nut, 1/4 inch

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

moving parts to stop before leaving the operating

position.

3. Unlatch the seat and tilt the seat up.

4. First disconnect the negative battery cable and ground

wire from the negative (–) battery terminal (Fig. 61).

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

battery terminal. Then remove the positive (red) battery cable (Fig. 61).

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

clamp (Fig. 61).

7. Remove the battery.

Adding Water to the Battery

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

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

1. Remove the battery from the machine.

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

• When removing or installing the battery, do not

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

• Do not allow metal tools to short between the

battery terminals and metal parts of the machine.

Warning

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

• Always Disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always Reconnect the positive (red) battery

cable before reconnecting the negative (black) cable.

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

3. Remove the vent caps from the battery (Fig. 60).

4. Slowly pour distilled water into each battery cell until

the level is up to the upper line (Fig. 60) on the battery case.

Important Do not overfill the battery because

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

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

Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 60) on the battery case.

6. Reinstall battery vent caps.

Charging the Battery

Warning

Charging the battery produces gasses that can explode.

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

Important Always keep the battery fully charged

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

1. Remove the battery from the chassis; refer to Removing the Battery, page 44.

2. Check the electrolyte level; refer to Checking Electrolyte Level, page 43.

3. Make sure the filler caps are installed in battery. Charge battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4–6 amps.

4. When the battery is fully charged, unplug the charger from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 62).

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

to 13 psi (90 kPa)

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

position.

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

tension.

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

support arm on the same side. Refer to Adjusting the Front–to–Rear Mower Pitch on page 46.

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

support arm for that chain. Refer to Adjusting the Front–to–Rear Mower Pitch on page 46.

Leveling the Mower Side–to–Side

3 1

Figure 62

1. Positive Battery Post

2. Negative Battery Post

3. Red (+) Charger Lead

4. Black (–) Charger Lead

5. Install the battery in the machine and connect the battery cables; refer to Installing the Battery on page 43.

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

Leveling the Mower at Three Positions

m–4970

1. Position the right blade front-to-rear (Fig. 63).

2. Measure the right blade at the B location (Fig. 63),

from a level surface to the cutting edge of the blade tip (Fig. 64).

3. Record this measurement. This measurement needs to

be 3–1/8 to 3–1/4 inches.

4. Position the left blade front-to-rear (Fig. 63).

5. Measure the left blade at the C location (Fig. 63), from

a level surface to the cutting edge of the blade tip (Fig. 64).

6. Record this measurement. This measurement needs to

be 3–1/8 to 3–1/4 inches.

F ront

m–1078

Figure 63

Important There are only three measuring positions

needed to level the mower.

Setting Up the Machine

1. Position mower on a flat surface.

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

the neutral locked position and set the parking brake.

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

MEASURE FROM CUTTING EDGE TO A LEVEL SURFACE

Figure 64

m–2539

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

correct, loosen the bolt attaching the rear chain to the rear support arm (Fig. 65).

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

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

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

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

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

10.Adjust the opposite side if needed.

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

(Fig. 66). If it is not correct, proceed to the following steps.

F ront

m–1078

Front

m–6830

Figure 65

1. Rear chain

2. Rear support arm

3. Bolt

4. Jam Nut

5. Adjustment bolt

6. Front swivel

7. Front support arm

Adjusting the Front–to–Rear Mower Pitch

1. Position the right blade front-to-rear (Fig. 66).

2. Measure the right blade at the A location (Fig. 66),

from a level surface to the cutting edge of the blade tip (Fig. 67).

3. Record this measurement.

4. Measure the right blade at the B location (Fig. 66),

from a level surface to the cutting edge of the blade tip (Fig. 67).

5. Record this measurement.

Figure 66

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

m–2539

Figure 67

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

7. Loosen the front swivel jam nuts, at the front of the right and left swivels, approximately a 1/2 inch (13 mm) (Fig. 68).

8. Adjust the lift nuts on both the left and the right side of the machine to achieve 1/4 to 3/8 inch (6 to 10 mm)

lower in front at A than in the rear at B (Fig. 68).

9. Tighten both swivel jam nuts against the front swivel

to lock the height.

10.Check to make sure there is equal tension on the chains and adjust again if needed.

Adjusting the Compression Spring

1. Raise the mower lift lever to the transport position (Fig. 16).

2. Check the distance between the two large washers, it needs to be 10–1/2 inches (26.7 cm) (Fig. 68).

3. Adjust this distance, by loosening the spring jam nut and turning the nut in front of each spring (Fig. 68). Turning the nut clockwise will shorten the spring; counter–clockwise will lengthen the spring.

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

nut (Fig. 68).

Warning

m–6831

Front

Figure 68

1. 10–1/2 inch (26.7 cm) between the large washers

2. Front nut

3. Spring jam nut

4. Front swivel

5. Swivel jam nut

6. Lift nut

7. Front support arm

8. Large washer

Cleaning Under the Mower

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

• Use jack stands when supporting the machine.

• Do not use hydraulic jacks.

Inspecting the Belts

Inspect all belts every 100 hours.

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

any other damage. Replace damaged belts.

Replacing the Mower Belt

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

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

Remove the grass buildup under the mower daily.

1. Position the mower on a flat surface.

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

the neutral locked position and set the parking brake.

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

4. Raise the mower to the transport position.

5. Lift the front of the machine and support the machine

using jack stands.

3. Remove the belt covers (Fig. 70).

4. Loosen the nut securing the idler plate and move the

idler plate to relieve the belt tension on the idler pulley (Fig. 72).

5. Remove the nut, washer and belt guide from the rear

leftside pulley (Fig. 69).

6. Remove the mower belt from the belt guides and

remove the belt (Fig. 69).

7. Install the new mower belt around the mower spindle

pulleys, mower idler pulley, into the belt guides, into rear idler arm assembly, and the clutch (Fig. 69).

8. Install the belt guide with a washer and nut onto the

rear leftside pulley (Fig. 69).

Important Check the amount of twist in the belt

between the pulleys. Make sure it is only what is specified in Figure 69.

m–6824

2 6

m–7829

Figure 69

1. Clutch

2. Mower belt

3. 1/4 turn belt twist

4. Belt guide

5. Mower spindle pulley

6. Mower idler pulley

7. Belt guide installed

8. Nut

9. Washer

10. Rear leftside pulley

9. Adjust the belt tension, refer to Adjusting the Mower

Belt Tension; page 48.

10.Install the belt covers and close the latches (Fig. 70).

1. Belt cover 2. Latch

Figure 70

Adjusting the Mower Belt Tension

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

the neutral locked position and set the parking brake.

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

moving parts to stop before leaving the operating position.

3. Raise the mower to the transport position.

Important Check the amount of twist in the belt

between the pulleys. Make sure it is only what is specified in Figure 69.

Important Check and make sure the belt is installed

into both the front and rear belt guides (Fig 71).

4. Check the belt tension. The spring loaded idler center

bolt needs to be near the top alignment hole in left support plate (Fig 71).

1 2

M–4417

Figure 71

1. Center bolt

2. Alignment hole

3. Left support plate

4. Spring loaded idler

5. If adjustment is required, loosen the mower idler plate and adjust it (Fig. 72).

6. Insert a ratchet or breaker bar into the square hole in the mower idler plate to adjust the tension (Fig. 72).

7. To increase belt tension, rotate the mower idler plate until resistance is felt and rotation stops. Do not go past when it stops (Fig. 72).

m–6825 1

Figure 73

1. Spring loaded idler pulley

2. Top alignment hole

3. 0 to 1/4 inch gap (0 to 6 mm)

4. Idler pulley arm

5. Belt

6. Rubber bumper

11. If the mower idler plate contacts the end of the adjustment slot and more belt tension is required, a small change to the right side fixed idler can create more belt tension adjustment (Fig. 74).

8. Tighten the idler plate bolts (Fig. 72).

m–6826

Figure 72

1. Mower idler plate

2. Square hole

3. Ratchet or breaker bar

4. Idler plate bolt

9. Check the distance from the rubber stop and the arm of

the spring loaded idler pulley when the idler plate is tightened. It needs to be 0 to 1/4 inch (0 to 6 mm) from the rubber stop (Fig. 73).

10.Adjust the belt tension and the idler plate, if necessary,

and tighten all hardware securely (Fig. 72).

m–3746

Figure 74

1. Fixed Idler 2. Adjustment slot

Replacing the Grass Deflector

Warning

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

• Never operate the lawn mower unless you

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

• Make sure the grass deflector is in the

down position.

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

the deflector to the pivot brackets (Fig. 75). Remove damaged or worn grass deflector.

2. Place spacer and spring onto grass deflector. Place the L end of spring behind deck edge.

Note: Make sure the L end of spring is installed behind

deck edge before installing the bolt as shown in figure 75.

3. Install bolt and nut. Place J hook end of spring around grass deflector (Fig. 75).

Important The grass deflector must be able to lower

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

m–6846

1. Bolt

2. Spacer

3. Locknut

4. Spring

5. Spring installed

Figure 75

4 8

7 3

6. Grass Deflector

7. L end of spring, place behind deck edge before installing bolt

8. J hook end of spring

Wiring Diagram

Cleaning and Storage

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

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

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

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

Important You can wash the machine with mild

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

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

Cleaner, page 31.

A. Add a petroleum based stabilizer/conditioner to

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

based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effective when

mixed with fresh gasoline and used at all times.

B. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

refer to Servicing the Fuel Tank, page 34. D. Restart engine and run it until it stops. E. Choke or prime the engine. Start and run engine

until it will not start. Operate primer, if equipped

on machine, several times to ensure fuel remains in

primer system.

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

Lubrication, page 35.

5. Change the crankcase oil; refer to Servicing the

Engine Oil, page 32.

6. Change the hydraulic filter; refer to Servicing the

Hydraulic System, page 38.

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

Pressure, page 37.

8. Charge the battery; refer to Servicing the Battery

page 43.

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

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

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

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

the Cutting Blades on page 29.

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

over 30 days. Prepare machine for storage as follows.

F. Dispose of fuel properly. Recycle as per local

codes.

Important Do not store stabilizer/conditioned gasoline

over 90 days.

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

refer to Servicing the Spark Plug, page 33. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

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

replace any part that is damaged or defective.

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

available from your Authorized Service Dealer.

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

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

Troubleshooting

g,,

Problem Possible Causes Corrective Action

Starter does not crank

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

1. Blade control (PTO) is engaged.

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

3. Operator is not seated.

4. Battery is dead.

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

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

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

2. Choke is not on. 2. Move choke lever to on.

3. Air cleaner is dirty. 3. Clean or replace air cleaner

4. Spark plug wires are loose or disconnected.

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

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

1. Move blade control (PTO) to disengaged.

3. Sit on the seat.

4. Charge the battery.

5. Check electrical connections for good contact.

Dealer.

element.

4. Install wires on spark plug.

5. Install new, correctly gapped spark plugs.

Engine loses power.

Engine overheats.

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

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

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

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

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

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

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

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

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

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

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

7. Contact Authorized Service Dealer.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plugs.

7. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

Problem Corrective ActionPossible Causes

Machine does not drive.

Abnormal vibration.

Uneven cutting height.

1. Traction belt is worn, loose or broken.

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

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

4. Tension spring is not connected.

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

2. Blade mounting bolt is loose. 2. Tighten blade mounting bolt.

3. Engine mounting bolts are loose.

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

5. Engine pulley is damaged. 5. Contact Authorized Service

6. Blade spindle bent. 6. Contact Authorized Service

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

1. Contact Authorized Service Dealer.

Dealer.

4. Connect the tension spring.

1. Install new cutting blade(s).

3. Tighten engine mounting bolts.

4. Tighten the appropriate pulley.

Dealer.

Blades do not rotate.

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

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

4. Anti–scalp roller is not set

correctly.

5. Underside of mower is dirty.

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

7. Blade spindle bent. 7. Contact Authorized Service

1. Mower belt is worn, loose or

broken.

2. Mower belt is off pulley. 2. Install the mower belt and

3. Deck belt is worn, loose or

broken.

4. Deck belt is off pulley. 4. Install deck pulley and check

4. Adjust gage wheel height.

5. Clean the underside of the mower.

Dealer.

1. Install new drive belt.

check adjusting plate and belt guides for correct position.

3. Install new deck belt.

the idler pulley, idler arm and spring for correct position and function.

LCE

The Toro Total Coverage Guarantee

A Limited Warranty

Conditions and Products Covered

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

Products

• All Products 1 year

• All Spindles 2 years parts and labor;

• Engines/Hydraulic Systems* on

the following:

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

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

ProLine Mid-Size Mowers Mid-Mount Z’s

• Electric Clutch on 500 Series Mid-Mount Z’s

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

This warranty applies to:

• Outfront and Mid-Mount Z’s

• ProLine Mid-Size Mowers

• Groundsmaster Riding Mowers

• Turf Maintenance Equipment

• Debris Management Equipment

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

engine manufacturer.



Riding Mowers

Warranty Period

third year, parts only

2 years

Instructions for Obtaining Warranty Service

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

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

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

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

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

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

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

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

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

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

• Pickup and delivery charges.

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

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

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

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

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

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

Owner Responsibilities

Items and Conditions Not Covered

General Conditions

Countries Other than the United States or Canada

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

Part No. 374-0037 Rev. D

Toro 74239, 74244 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual