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Toro 74253, 74254 Operator's Manual

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Page 1
FormNo.3361-722RevA
Z580ZMaster TURBOFORCE
®
witha60inor72in
®
SideDischarge
Mower
ModelNo.74253—SerialNo.290000001andUp
ModelNo.74254—SerialNo.290000001andUp
Page 2
Warning
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedonthe engineofthismachine,asparkarresterisincorporated withthemuferassembly .
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Figure1
1.Modelandserialnumberlocation
Important:Thisengineisequippedwithaspark arrestermufer.ItisaviolationofCaliforniaPublic ResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered, orgrass-coveredlandwithoutasparkarrester mufermaintainedinworkingorder,ortheengine constricted,equipped,andmaintainedforthe preventionofre.Otherstatesorfederalareasmay havesimilarlaws.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Theenclosed
Engine Owner’ s Man ual
issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
Introduction
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .T oro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready .Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
SlopeChart..........................................................6
SafetyandInstructionalDecals.............................7
ProductOverview......................................................13
Controls.............................................................13
Operation...................................................................15
AddingFuel.......................................................15
CheckingtheEngineOilLevel............................16
SwitchingtheFuelTanks....................................16
©2009—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.T oro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
UsingtheRolloverProtectionSystem
(ROPS)..........................................................16
ThinkSafetyFirst...............................................18
OperatingtheParkingBrake...............................19
StartingandStoppingtheEngine........................19
OperatingthePowerTakeOff(PTO).................20
TheSafetyInterlockSystem................................20
DrivingForwardorBackward.............................21
StoppingtheMachine.........................................22
AdjustingtheHeight-of-Cut...............................22
AdjustingtheAnti-ScalpRollers.........................22
AdjustingtheFlowBafe...................................23
PositioningtheFlowBafe.................................24
PositioningtheSeat............................................25
UnlatchingtheSeat.............................................25
PushingtheMachinebyHand.............................25
UsingtheSideDischarge....................................26
BreakingInaNewMachine................................26
TransportingMachines.......................................26
LoadingMachines..............................................26
OperatingTips...................................................27
Maintenance...............................................................29
RecommendedMaintenanceSchedule(s)................29
Lubrication.............................................................30
GreasingandLubrication...................................30
GreasingtheBrakePivot....................................31
GreasingtheMowerDeckandBelt
Idlers..............................................................31
LubricateCasterWheelHubs.............................32
EngineMaintenance...............................................33
ServicingtheAirCleaner....................................33
ServicingtheEngineOil.....................................33
ServicingtheSparkPlug.....................................35
FuelSystemMaintenance.......................................37
ServicingtheElectronicFuelInjection
System............................................................37
ServicingtheFuelFilters....................................37
ServicingtheFuelTank......................................37
ElectricalSystemMaintenance................................38
ServicingtheBattery...........................................38
ServicingtheFuses.............................................39
DriveSystemMaintenance.....................................40
AdjustingtheTracking........................................40
CheckingtheTirePressure.................................41
CheckingtheWheelHubSlottedNut..................41
AdjustingtheCasterPivotBearing......................41
ServicingtheGearBox.......................................42
AdjustingtheElectricClutch..............................42
CoolingSystemMaintenance..................................44
ServicingtheCoolingSystem..............................44
BrakeMaintenance.................................................45
AdjustingtheParkingBrake................................45
BeltMaintenance....................................................46
InspectingtheBelts............................................46
ReplacingtheMowerBelt...................................46
AdjustingtheMowerBeltTensionfor72in
MowersOnly..................................................47
ReplacingthePTODriveBelt.............................47
ReplacingthePumpDriveBelt...........................48
ControlsSystemMaintenance.................................49
AdjustingtheControlHandleNeutral
Position..........................................................49
HydraulicSystemMaintenance...............................50
ServicingtheHydraulicSystem...........................50
SettingtheHydraulicPumpNeutral
Position..........................................................52
MowerDeckMaintenance......................................54
LevelingtheMoweratThreePositions................54
ServicingtheCuttingBlades...............................56
ReplacingtheGrassDeector.............................58
Cleaning.................................................................58
CleaningUndertheMower.................................58
WasteDisposal...................................................58
Storage.......................................................................59
CleaningandStorage..........................................59
Troubleshooting.........................................................60
Schematics.................................................................62
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Safety
•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol,whichmeans CAUTION,WARNING,orDANGER-“personal safetyinstruction."Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
SafeOperatingPractices
ThefollowinginstructionsarefromANSIstandard B71.4-2004.
Training
•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner’sresponsibilitytoexplain thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.
–Useonlyanapprovedcontainer
–Neverrefuelordrainthemachineindoors.
–Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling. Donotsmoke.
•Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
•Neverrunanengineinanenclosedarea.
•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator’sposition.Useseatbelts.
•Neverraisemowerwiththebladesrunning.
•NeveroperatewithoutthePTOshield,orother guardssecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly .
•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.
•Donotchangetheenginegovernorsettingor overspeedtheengine.
•Stoponlevelground,lowerimplements,disengage drives,engageparkingbrake,shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.
•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunits.
Preparation
•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.
•Nevercarrypassengersandkeeppetsandbystanders away.
•Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.
•Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.
•Beawareofthemowerdischargedirectionanddo notpointitatanyone.
•Donotoperatethemowerundertheinuenceof alcoholordrugs.
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•Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
SlopeOperation
•Donotmowslopesgreaterthan15degrees.
•Donotmowneardrop-offs,ditches,steepbanks orwater.Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury,death ordrowning.
•Checktheareatobemowedandneverfoldthe ROPSinareaswherethereareslopes,dropoffsor water.
•Lowertherollbaronlywhenabsolutelynecessary. Donotweartheseatbeltwiththerollbarfolded down.
•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforedriving underanyobjectsanddonotcontactthem.
Maintenanceandstorage
•Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.
•Donotmakesuddenturnsorrapidspeedchanges.
•Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater.
•Reducespeedanduseextremecautiononslopes.
•Removeormarkobstaclessuchasrocks,treelimbs, etc.fromthemowingarea.Tallgrasscanhide obstacles.
•Watchforditches,holes,rocks,dips,andrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.
•Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.
•Beawarethatlossoftractionmayoccurgoing downhill.Weighttransfertothefrontwheelsmay causedrivewheelstoslipandcauselossofbraking andsteering.
•Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.
•Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprovestability.
•Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.
•Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.
•Cleangrassanddebrisfromcuttingunits,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear ame.
•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.
•Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.
•Usejackstandstosupportcomponentswhen required.
•Carefullyreleasepressurefromcomponentswith storedenergy.
•Disconnectbatteryorremovesparkplugwirebefore makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Reconnectpositiverst andnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.
•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
UsingtheRolloverProtectionSystem (ROPS)
•Keeptherollbarintheraisedandlockedposition andusetheseatbeltwhenoperatingthemachine.
•Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.
•Beawarethereisnorolloverprotectionwhenthe rollbarisdown.
•Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.W ear protectiveclothinganduseinsulatedtools.
•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.
•UseonlyToroapprovedattachments.W arrantymay bevoidedifusedwithunapprovedattachments.
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SlopeChart6SafetyandInstructional Decals
Page 7
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
58-6520
1.Grease
1-403005
65-2690
1-523552
66-1340
1-643253
68-8340
98-4387
54-9220
1.Warning—wearhearingprotection.
7
Page 8
98-5954
107-1857
104-2449
107-1860
1.Heightofcut
105-7798
107-1613
8
Page 9
107-1861
107-2102
107-1864
107-2112
107-2114
9
Page 10
108-5981
109-7949
110-3851
1.Removetheignitionkeyandreadtheinstructionsbefore servicingorperformingmaintenance.
110-2067
110-2068
1.ReadtheOperator’sManual.
1.Removetheignitionkey andreadtheinstructions beforeservicingor performingmaintenance.
1.Cutting/dismemberment hazard,fanand entanglementhazard, belt.
10
110-3852
2.Continuoustonesignals theuserthatengineis overheating.
110-3853
2.Removetheignitionkey andreadtheinstructions beforeservicingor performingmaintenance.
Page 11
110-6220
117-7839
Manufacturer’sMark
110-6221
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
1.Interval
2.PowerT ake-off(PTO)
3.Parkingbrake
4.Neutral
5.Operatorpresenceswitch
6.Battery
112-8651
117–0919
1.Fast
2.Continuousvariable setting
3.Slow
117–2718
117-7838
11
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106-7492
106-9989
107-9309
1.Warning—readtheOperator’sManualforinformationonchargingthebattery;containslead;donotdiscard.
2.ReadtheOperator’sManual.
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ProductOverview
Figure3
1.Liftassistlever6.Controls
2.Height-of-cutlever7.Fuelcap(bothsides)
3.Motioncontrollevers8.Parkingbrakelever
4.Rollbar
5.Seatbelt
9.Casterwheel
10.Mowerdeck
110-0819
Figure4
1.Fueltankcap
2.Malfunctionindicatorlight (MIL)
3.EngineTemperaturelight7.Ignitionswitch
4.Throttlecontrol
5.PTOSwitch
6.Hourmeter/Safety interlockdisplay
HourMeter
Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance (Figure4).
Controls
Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure3andFigure4).
SafetyInterlockIndicators
Therearesymbolsonthehourmeterandtheyindicate withablacktrianglethattheinterlockcomponentisin thecorrectposition(Figure5).
BatteryIndicatorLight
WhentheignitionkeyisinitiallyturnedtotheRun positionforafewseconds,thebatteryvoltagewillbe displayedintheareawherethehoursarenormally displayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure5).
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Figure5
1.Safetyinterlocksymbols
2.Hourmeter
3.Batterylight
ThrottleControl
ThethrottlecontrolisvariablebetweenFastandSlow.
BladeControlSwitch(PTO)
Movetheselectorvalvetothelefthand(LH)or righthand(RH)positionforoperation.
MalfunctionIndicatorLight
Theelectroniccontrolunit(ECU)continuously monitorstheoperationofthefuelsystem.
Ifthemalfunctionindicatorlight(MIL)illuminates, duringoperation,theelectroniccontrolunit(ECU)has detectedaproblemorfaultinthedirectfuelinjection (DFI)system.
OncetheMILilluminates,initialtroubleshooting checksshouldbemade.RefertotheMILsectionunder Toubleshooting.
Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedServiceDealer isnecessary.
Thebladecontrolswitch(PTO)isusedtoengagethe electricclutchtodrivethemowerbladeswiththemotion controlleversinthecenter,un-lockedposition.Pullthe switchuptoengagethebladesandrelease.Todisengage theblades,pushthebladecontrolswitch(PTO)down.
NeutralLockPosition
Theneutrallockpositionisusedwiththesafetyinterlock systemandtodetermineneutralposition.
IgnitionSwitch
Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.
TemperatureLight
Thetemperaturelightcomesonwhentheengineisover heating(Figure4).
AudibleAlarm
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
Thismachinehasanaudiblealarmthatalertstheuser toturnofftheengineorenginedamagecanoccurfrom overheating.RefertoServicingtheCoolingSystemin Maintenance.
FuelSelectorValve
Thefuelselectorvalveislocatedundertheleftsideof theseat(Figure6).
Closethefuelselectorvalvewhentransportingor storingmower.
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Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
AddingFuel
Useunleadedregulargasolinesuitableforautomotive use(87pumpoctaneminimum).
Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontainingmore than10%ethanolbecausethefuelsystemcouldbe damaged.Donotmixoilwithgasoline.
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areor explosionfromgasolinecanburnyouand othersandcandamageproperty.
•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupany gasolinethatspills.
•Neverllthefueltankinsideanenclosed trailer.
•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4 to1/2inch(6to13mm)belowthebottomof thellerneck.Thisemptyspaceinthetank allowsgasolinetoexpand.
•Neversmokewhenhandlinggasoline,and stayawayfromanopenameorwhere gasolinefumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Never buymorethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaust systeminplaceandinproperworking condition.
Incertainconditionsduringfueling,static electricitycanbereleasedcausingaspark whichcanignitethegasolinevapors.Are orexplosionfromgasolinecanburnyouand othersandcandamageproperty.
•Alwaysplacegasolinecontainersonthe groundawayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsidea vehicleoronatruckortrailerbedbecause interiorcarpetsorplastictruckbedliners mayinsulatethecontainerandslowtheloss ofanystaticcharge.
•Whenpractical,removegas-powered equipmentfromthetruckortrailerand refueltheequipmentwithitswheelsonthe ground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfroma portablecontainer,ratherthanfroma gasolinedispensernozzle.
•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimof thefueltankorcontaineropeningatall timesuntilfuelingiscomplete.
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditioneropening.
•Keepgasawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting
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Important:Donotusefueladditivescontaining methanolorethanol.
Addthecorrectamountofgasstabilizer/conditioner tothegas.
Note:Afuelstabilizer/conditionerismosteffective whenmixedwithfreshgasoline.Tominimizethe chanceofvarnishdepositsinthefuelsystem,usefuel stabilizeratalltimes.
FillingtheFuelTank
1.Shuttheengineoffandsettheparkingbrake.
2.Cleanaroundeachfueltankcapandremovethecap.
3.Addunleadedregulargasolinetobothfueltanks, untilthelevelis1/4to1/2inch(6mmto13mm) belowthebottomofthellerneck.
Thisspaceinthetankallowsgasolinetoexpand. Donotllthefueltankscompletelyfull.
4.Installfueltankcapssecurely.
5.Wipeupanygasolinethatmayhavespilled.
Figure6
1.Hydraulictank2.Fuelselectorvalve
UsingtheRolloverProtection System(ROPS)
CheckingtheEngineOilLevel
Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelin,page
SwitchingtheFuelTanks
Important:Donotrunthemachineoutoffueland
avoidrunningthemachinewithalowfuellevel.
Thefuelselectorvalveislocatedundertheleftsideof theseat.Unlatchtheseatandraiseittoaccessthevalve.
Theunithastwofueltanks.Onetankisontheleft sideandoneontherightside.Eachtankconnectsto thefuelselectorvalve.Fromthereacommonfuelline leadstotheengine(Figure6).
Tousetheleftsidefueltankrotatethefuelselector valvetotheLH,lefthandlocation.Tousetheright sidefueltankrotatethefuelselectorvalvetotheRH, righthandlocation(Figure6).
Closethefuelselectorvalvebeforetransportingor storingmachine.
Toavoidinjuryordeathfromrollover:keepthe rollbarintheraisedlockedpositionanduse theseatbelt.
Ensurethattherearpartoftheseatissecured withtheseatlatch.
Thereisnorolloverprotectionwhentherollbar isinthedownposition.
•Lowertherollbaronlywhenabsolutely necessary.
•Donotweartheseatbeltwhentherollbaris inthedownposition.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance permits.
•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)before drivingunderanyobjectsanddonotcontact them.
16
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Important:Lowertherollbaronlywhen
G004955
1
2
3
4
absolutelynecessary.
1.Removethehairpincotterpinsandremovethetwo pins(Figure8).
2.Lowertherollbartothedownposition.Thereare twodownpositions.SeeFigure7forthepositions.
3.Installthetwopinsandsecurethemwiththe hairpincotterpins(Figure8).
Figure7
1.Fulldownposition2.Downpositionwithbagger installed
Figure8
1.Rollbar3.Pin
2.Raisedposition4.Hairpincotterpin
Important:Ensurethattherearpartofthe seatissecuredwiththeseatlatch.
4.Toraisetherollbar,removethehairpincotterpins andremovethetwopins(Figure8).
5.Raisetherollbartotheuprightpositionandinstall thetwopinsandsecurethemwiththehairpincotter pins(Figure8).
Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.
17
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ThinkSafetyFirst
Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.
Operatingonwetgrassorsteepslopescan causeslidingandlossofcontrol.
Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.
Thereisnorolloverprotectionwhentheroll barisdown.
Alwayskeeptherollbarintheraisedandlocked positionandusetheseatbelt.
Readandfollowtherolloverprotection instructionsandwarnings.
Toavoidlossofcontrolandpossibilityof rollover:
•Donotoperateneardrop-offsornearwater.
•Donotoperateonslopesgreaterthan 15degrees.
•Reducespeedanduseextremecautionon slopes.
•Avoidsuddenturnsorrapidspeedchanges.
Figure9
1.SafeZone-usethe ZMasterhereonslopes lessthan15degreesor atareas.
2.Usewalkbehindmower and/orhandtrimmernear drop-offsandwater.
3.Water
Thismachineproducessoundlevelsinexcess of85dBAattheoperatorsearandcancause hearinglossthroughextendedperiodsof exposure.
Wearhearingprotectionwhenoperatingthis machine.
Theuseofprotectiveequipmentforeyes,ears,feetand headisrecommended.
1.Warning—wearhearingprotection
18
Figure10
Page 19
OperatingtheParkingBrake
StartingandStoppingthe
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.
SettingtheParkingBrake
1.Movethemotioncontrollevers(Figure17)outto theneutrallockposition.
2.Pullupandbackontheparkingbrakelevertoset theparkingbrake(Figure11).Theparkingbrake levershouldstayrmlyintheengagedposition.
Parkingbrakemaynotholdmachineparked onaslopeandcouldcausepersonalinjuryor propertydamage.
Donotparkonslopesunlesswheelsare chockedorblocked
ReleasingtheParkingBrake
Engine
StartingtheEngine
Note:Thismachinedoesnothaveamanualchoke.
Thismachineisequippedwithandigitalfuelinjection (DFI)system.
1.RaisetheROPSupandlockintoplace,sitonthe seatandfastentheseatbelt.
2.Movethemotioncontrolstoneutrallocked position.
3.Settheparkingbrake;refertoSettingtheParking Brake.
4.MovethePTO(powertakeoff)switchtotheOff position(Figure12).
Pushforwardanddownontheparkingbrakelever toreleasetheparkingbrake(Figure11).Theparking brakeisdisengagedandtheleverwillrestagainstthe brakestop.
Figure11
1.Parkingbrake-ON3.BrakeStop
2.Parkingbrake-OFF
Figure12
1.PTO—on2.PTO—off
5.MovethethrottlecontrolmidwaybetweentheSlow andFastpositions(Figure13).
1.Throttle—fast
6.TurntheignitionkeytotheStartposition (Figure14).Whentheenginesstarts,releasethekey.
19
Figure13
2.Throttle—slow
Page 20
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
OperatingthePowerTakeOff (PTO)
Thepowertakeoff(PTO)switchstartsandstopsthe mowerbladesandanypoweredattachments.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.
Figure14
1.Off3.Start
2.Run
StoppingtheEngine
1.PushthePTOtotheOffposition(Figure12).
2.MovethethrottlelevermidwaybetweentheSlow andFastpositions(Figure13).
3.Lettheengineidlefor60seconds.
EngagingthePTO
1.Iftheengineiscold,allowtheenginetowarmup5 to10minutesbeforeengagingthePTO.
2.Whileseatedintheseat,releasethepressureonthe tractioncontrolleversandplaceinneutral.
3.Placethethrottleinthefastposition.
Note:EngagingthePTOwiththethrottleatthe halforlesspositionwillcauseexcessiveweartothe drivebelts.
4.Pulloutonthepowertakeoff(PTO)switchto engageit(Figure15).
4.TurntheignitionkeytotheOffpositionand removethekey(Figure14).
5.Closethefuelshutoffvalvebeforetransportingor storingthemachine.Referto,page.
Important:Makesurethatthefuelshutoff valveisclosedbeforetransportingorstoring themachine,asfuelleakagemayoccur.Setthe parkingbrakebeforetransporting.Makesure toremovethekeyasthefuelpumpmayrun andcausethebatterytolosecharge.
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.
Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.
Figure15
1.PTO-On2.PTO-Off
DisengagingthePTO
Todisengage,pushthePTOswitchtotheoffposition (Figure15).
TheSafetyInterlockSystem
Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.
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UnderstandingtheSafetyInterlock System
Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:
•Theparkingbrakeisengaged.
•Thepowertakeoff(PTO)isdisengaged.
•Themotioncontrolleversareintheneutrallocked position
Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOisengaged.
theparkingbrake,engagethePTOandriseslightly fromtheseat;theengineshouldstop.
4.Sittingontheseat,engagetheparkingbrake,move thePTOswitchtooffandmovethemotioncontrol leverstoneutrallockposition.Nowstarttheengine. Whiletheengineisrunning,centereithermotion controlandmove(forwardorreverse);theengine shouldstop.Repeatforothermotioncontrol.
5.Sittingontheseat,disengagetheparkingbrake, movethePTOswitchtooffandmovethemotion controlleverstoneutrallockposition.Trystarting theengine;theengineshouldnotcrank.
Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.
Figure16
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
TestingtheSafetyInterlockSystem
ServiceInterval:Beforeeachuseordaily
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
Machinecanspinveryrapidly.Operatormay losecontrolofmachineandcausepersonal injuryordamagetomachine.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemaking sharpturns.
DrivingForward
1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakein,page.
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorizedService Dealerrepairthesafetysystemimmediately .
1.Sittingontheseat,engagetheparkingbrakeand movethePTOtoon.Trystartingtheengine;the engineshouldnotcrank.
2.Sittingontheseat,engagetheparkingbrakeand movethePTOtooff.Moveeithermotioncontrol lever(outofneutrallockedposition).Trystarting theengine;theengineshouldnotcrank.Repeatfor othercontrollever.
3.Sittingontheseat,engagetheparkingbrake, movethePTOswitchtooffandmovethemotion controlleverstoneutrallockposition.Nowstart theengine.Whiletheengineisrunning,release
2.Movetheleverstothecenter,un-lockedposition.
3.Togoforward,slowlypushthemotioncontrol leversforward(Figure17).
Note:Theenginewillkillifthetractioncontrol leversaremovedwiththeparkingbrakeengaged.
Togostraight,applyequalpressuretobothmotion controllevers(Figure17).
Toturn,movethemotioncontrollevertoward neutralinthedirectionyouwanttoturn(Figure17).
Thefartheryoumovethetractioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.
Tostop,pullthemotioncontrolleverstotheneutral position.
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1.Motioncontrol lever-neutrallockposition
2.Centerun-lockposition
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileit isunattended.
Alwaysremovetheignitionkeyandsetthe parkingbrakewhenleavingthemachine unattended,evenifjustforafewminutes.
AdjustingtheHeight-of-Cut
Theheight-of-cutisadjustedfrom1-1/2to5inch (38to127mm)in1/4inch(6mm)incrementsby relocatingthepinintodifferentholelocations.
1.Raisetheheight-of-cutlevertothetransport position(alsothe5inch(127mm)cuttingheight position)(Figure18).
Figure17
3.Forward
4.Backward
DrivingBackward
1.Movetheleverstothecenter,un-lockedposition.
2.7
Togobackward,slowlypullthemotioncontrol leversrearward(Figure17).
Togostraight,applyequalpressuretobothmotion controllevers(Figure17).
Toturn,releasepressureonthemotioncontrollever towardthedirectionyouwanttoturn(Figure17).
Tostop,pushthemotioncontrolleverstothe neutralposition.
StoppingtheMachine
Tostopthemachine,movethetractioncontrollevers toneutralandmovetolockedposition,disengagethe powertakeoff(PTO),andturntheignitionkeytooff.
Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakein,page.Rememberto removethekeyfromtheignitionswitch.
Figure18
1.Heightofcutlever
2.Pin
2.Toadjust,removethepinfromtheheight-of-cut bracket(Figure18).
3.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(Figure18).
4.Movethelevertotheselectedheight.
AdjustingtheAnti-Scalp Rollers
Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
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2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Afteradjustingtheheight-of-cut,adjusttherollers byremovingtheangenut,bushing,spacer,and bolt(Figure19,Figure20andFigure21).
Note:Thetwomiddlerollerswillnothaveaspacer (Figure20).
4.Selectaholesotheanti-scalprollerispositionedto thenearestcorrespondingheight-of-cutdesired.
5.Installtheangenutbushing,spacer,andbolt. Torqueto40-45ft-lb(54-61N-m)(Figure19, Figure20andFigure21).
6.Repeatthisadjustmentontheotheranti-scalp rollers.
Figure19
1.Anti-scalproller4.FlangeNut
2.Spacer
3.Bushing
5.Bolt
Figure21
1.Anti-scalproller4.FlangeNut
2.Spacer
3.Bushing
5.Bolt
AdjustingtheFlowBafe
Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthecamlocks,swingtheleverupto loosenthecamlock(Figure22).
4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow .
Figure20
1.Anti-scalproller3.FlangeNut
2.Bushing4.Bolt
5.Swingtheleverbackovertotightenthebafeand camlocks(Figure22).
6.Ifthecamsdonotlockthebafeintoplaceoritis tootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilthedesiredlocking pressureisachieved.
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Figure22
1.Camlock
2.Lever
3.Rotatecamtoincreaseor decreaselockingpressure
4.Slot
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
PositionB
Usethispositionwhenbagging.
Figure24
Note:Iftheenginepowerdrawsdownandthemower
groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition.Thesuggesteduseforthis positionisafollows.
•Useforshort,lightgrassmowingconditions.
•Useindryconditions.
•Forsmallergrassclippings.
•Propelsgrassclippingsfartherawayfromthe mower.
PositionC
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows.
•Useintall,densegrassmowingconditions.
•Useinwetconditions.
•Lowerstheenginepowerconsumption.
•Allowsincreasedgroundspeedinheavyconditions.
•ThispositionissimilartothebenetsoftheT oro SFSmower.
Figure23
Figure25
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PositioningtheSeat
G008962
Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.
Toadjust,movetheleversidewaystounlockseat (Figure26).
Figure26
UnlatchingtheSeat
PushingtheMachine
1.Disengagethepowertakeoff(PTO)andturnthe ignitionkeytooff.Movetheleverstoneutrallocked positionandapplyparkingbrake.Removethekey.
2.Rotatetheby-passvalvescounterclockwise1turn topush.Thisallowshydraulicuidtoby-passthe pumpenablingthewheelstoturn(Figure28).
Important:Donotrotateby-passvalvesmore than1turn.Thispreventsvalvesfromcoming outofthebodyandcausinguidtorunout.
3.Disengageparkingbrakebeforepushing.
ChangingtoMachineOperation
Rotatetheby-passvalvesclockwise1turntooperate machine(Figure28).
Note:Donotovertightentheby-passvalves.
Themachinewillnotdriveunlessby-passvalvesare turnedin.
1.Movetheseattothemostrearwardposition.This willpreventinterferencewhentheseatisraised.
2.Pushtheseatlatchrearwardtounlatchtheseat.
3.Raisetheseatup.Thiswillallowaccesstothe machineundertheseat(Figure27).
Figure27
1.Seatlatch3.Seat
2.Fuelcap
Figure28
1.Hydraulictank2.By-passvalve
PushingtheMachinebyHand
Important:Alwayspushthemachinebyhand.
Nevertowthemachinebecausehydraulicdamage mayoccur.
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UsingtheSideDischarge
Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
Withoutthegrassdeector,dischargecover, orcompletegrasscatcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebriswill causeinjuryordeath.
•Neverremovethegrassdeectorfrom themowerbecausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
•Neverputyourhandsorfeetunderthe mower.
•Nevertrytoclearthedischargeareaor mowerbladesunlessyoumovethepower takeoff(PTO)totheoffposition,rotatethe ignitionkeytooffandremovethekey .
•Makesurethegrassdeectorisinthedown position.
BreakingInaNewMachine
Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew, placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.
Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow movingvehicleemblemisdangerousandcan leadtoaccidentscausingpersonalinjury.
Donotdrivemachineonapublicstreetor roadway.
LoadingMachines
Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure29). Thelowerrearsectionofthetractorframeextends backbetweentherearwheelsandservesasastopfor tippingbackward.Havingafullwidthrampprovides asurfacefortheframememberstocontactifthe unitstartstotipbackward.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.
Therampshouldbelongenoughsothattheangles donotexceed15degrees(Figure29).Asteeperangle maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.
Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.
TransportingMachines
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarylightingandmarkingasrequiredbylaw . Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.
Totransportthemachine:
•Lockthebrakeandblockthewheels.
•Securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes.
•Secureatrailertothetowingvehiclewithsafety chains.
Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.
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Loadingaunitontoatrailerortruckincreases thepossibilityofbackwardtip-overandcould causeseriousinjuryordeath.
•Useextremecautionwhenoperatingaunit onaramp.
•Useonlyasingle,fullwidthramp;DoNot useindividualrampsforeachsideofthe unit.
•Ifindividualrampsmustbeused,use enoughrampstocreateanunbrokenramp surfacewiderthantheunit.
themachinewithalowfuellevelanddonotrunthe machineoutoffuel.Alwaysallowthemachinetocool beforerellingthefueltanks.
FastThrottleSetting
Forbestmowingandmaximumaircirculation,operate theengineatthefastthrottleposition.Airisrequired tothoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower byuncutgrass.Alwaystrytohaveonesideofthe mowerfreefromuncutgrass,whichallowsairtobe drawnintothemower.
CuttingaLawnfortheFirstTime
•Donotexceeda15degreeanglebetween rampandgroundorbetweenrampand trailerortruck.
•Avoidsuddenaccelerationwhiledrivingunit uparamptoavoidtippingbackward.
•Avoidsuddendecelerationwhilebacking unitdownaramptoavoidtippingbackward.
Figure29
1.Trailer3.Notgreaterthan 15degrees
2.Fullwidthramp4.Fullwidthramp—sideview
Cutgrassslightlylongerthannormaltoensurethe cuttingheightofthemowerdoesnotscalpanyuneven ground.However,thecuttingheightusedinthepastis generallythebestonetouse.Whencuttinggrasslonger thansixinchestall,youmaywanttocutthelawntwice toensureanacceptablequalityofcut.
Cut1/3oftheGrassBlade
Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.
MowingDirection
Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.
MowatCorrectIntervals
Normally,moweveryfourdays.Butremember, grassgrowsatdifferentratesatdifferenttimes.So tomaintainthesamecuttingheight,whichisagood practice,mowmoreofteninearlyspring.Asthegrass growthrateslowsinmidsummer,mowlessfrequently. Ifyoucannotmowforanextendedperiod,rstmow atahighcuttingheight;thenmowagaintwodayslater atalowerheightsetting.
CuttingSpeed
OperatingTips
EnginePerformance
Forthebestengineperformance,llbothfueltanks fullbeforeoperatingthemachine.Avoidrunning
Toimprovecutquality,useaslowergroundspeedin certainconditions.
AvoidCuttingTooLow
Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.
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LongGrass
Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raise thecuttingheighthigherthanusualandcutthegrassat thissetting.Thencutthegrassagainusingthelower, normalsetting.
WhenStopping
Ifthemachine’sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyour lawn.T oavoidthis,moveontoapreviouslycutarea withthebladesengaged.
KeeptheUndersideoftheMower Clean
Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.
BladeMaintenance
Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.Checkthecutterblades dailyforsharpness,andforanywearordamage.File downanynicksandsharpenthebladesasnecessary.If abladeisdamagedorworn,replaceitimmediatelywith agenuineTOROreplacementblade.
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Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst25hours
Aftertherst100hours
Beforeeachuseordaily
Every25hours
Every50hours
MaintenanceProcedure
•Changetheengineoil.
•Checktheenginecoolingsystemlevel.
•Adjustthemowerbelttension(72inmowersonly).
•Checkthehydraulicuid.
•Changethehydrauliclter.
•Checkthewheelhubslottednut.
•Checkthewheellugnuts.
•Changegearboxoil.
•Checkthesafetysystem.
•Checktheengineoil.
•Checktheenginecoolingsystemlevel.
•Cleanthehydraulicoilcoolerandradiatorscreen.
•Checkthemowerblades.
•Cleanthemowerdeck.
•Greasethemowerdeckandspindles.
•Greasethemowerbeltidlerarm.
•Greasethepumpbeltidlerarm.
•Greasethedrivebeltidlerarm.
•Checkthehydraulicuid.
•Checkthetirepressure.
•CheckthePTOdrivebelt.
•Checkthepumpdrivebelt.
Every100hours
Every150hours
Every200hours
Every250hours
Every400hours
Every500hours
Yearlyorbeforestorage
•Changetheengineoil.(moreoftenindirtyordustyconditions)
•Checkthesparkplug.
•Checkthegearboxoillevel.
•Checktheenginecoolingsystemhoses.
•Inspectthebeltsforcracksandwear.
•Checkthehydraulichoses.
•Lubricatethemachinewithlightoil.
•Greasethebrakepivot.
•Changetheengineoillter.
•Checktheparkingbrakeadjustment.
•Checkorreplacetheairlter(moreoftenindirtyordustyconditions)
•Replacethefuellters(moreoftenindirtyordustyconditions).
•Checkthewheelhubslottednut.
•Checkthewheellugnuts.
•Adjustthecasterpivotbearing.
•Adjusttheelectricclutch.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Lubricatethecasterwheelhubs
Yearly
•Changethegearboxoil.
•Changetheenginecoolant.
•Changethehydrauliclterandoil.
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineoperator’smanualforadditionalmaintenanceprocedures.
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Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
Lubrication
GreasingandLubrication
LubricatethemachinewhenshownontheCheck ServiceReferenceAiddecal(Figure30).Greasemore frequentlywhenoperatingconditionsareextremely dustyorsandy.
GreaseType:General-purposegrease.
HowtoGrease
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.
5.Wipeupanyexcessgrease.
GreasingtheFrontCasterPivots
ServiceInterval:Yearly(moreoftenindirtyordusty
conditions).
1.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.
2.Removethehexplug.Threadagreasezerkintothe hole.
3.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.
4.Removethegreasezerkinthehole.Installthehex plugandcap.
Figure30
WheretoAddLightOilorSpray Lubrication
ServiceInterval:Every150hours
•Seatswitchactuator.
•Brakehandlepivot.
•Brakerodbushings.
•Motioncontrolbronzebushings.
WheretoAddGrease
LubricatethegreasettingsasshownontheCheck ServiceReferenceAiddecal(Figure30).
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GreasingtheBrakePivot
ServiceInterval:Every200hours—Greasethebrake
pivot.
Figure32
Figure31
GreasingtheMowerDeckand BeltIdlers
ServiceInterval:Every25hours—Greasethemower
deckandspindles.
Every25hours—Greasethemower beltidlerarm.
Every25hours—Greasethepump beltidlerarm.
Every25hours—Greasethedrive beltidlerarm.
GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.
Important:Makesurecuttingunitspindlesare fullofgreaseweekly.
5.Greasethepumpbeltidlerarm(Figure33).
Figure33
6.GreasethePTOdrivebeltidlerarm(Figure34).
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Greasetheidlerpulleypivot(Figure32).
4.Greasethettingsonthe3spindlebearings (Figure32).
Figure34
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LubricateCasterWheelHubs
ServiceInterval:Yearly
1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.
Figure35
1.Sealguard2.Spacernutwithwrench ats
2.Removethecasterwheelfromthecasterforks.
3.Removethesealguardsfromthewheelhub.
13.Torquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Makesure axledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .
Important:T opreventsealandbearingdamage, checkthebearingadjustmentoften.Spinthecaster tire.Thetireshouldnotspinfreely(morethan1or 2revolutions)orhaveanysideplay.Ifthewheel spinsfreely,adjusttorqueonspacernutuntilthere isaslightamountofdrag.Reapplythreadlocking adhesive.
4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthespacer nutstotheaxle.Removetheaxle(withtheother spacernutstillassembledtoit)fromthewheel assembly.
5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.
6.Packthebearingswithageneral-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note:Thesealsmustbereplaced.
8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontotheaxle withthewrenchatsfacingoutward.DoNotthread spacernutallofthewayontotheendoftheaxle. Leaveapproximately1/8inch(3mm)fromthe outersurfaceofthespacernuttotheendoftheaxle insidethenut.
9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.
10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
11.Insertthesecondbearingandnewsealintothe wheel.
12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.
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EngineMaintenance
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.
ServicingtheAirCleaner
Note:Checktheltersmorefrequentlyifoperating
conditionsareextremelydustyorsandy.
RemovingtheAirFilter
ServiceInterval:Every250hours(moreoftenindirty
ordustyconditions)
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasetheseatandtipitforward.
4.Raisetheradiatorcover.
5.Releasethelatchesontheaircleanerandpulltheair cleanercoveroffoftheaircleanerbody(Figure36).
6.Cleantheinsideoftheaircleanercoverwith compressedair.
7.Gentlyslidethelteroutoftheaircleanerbody (Figure36).Avoidknockingthelterintotheside ofthebody.
8.Inspectthelterfordamagebylookingintothe lterwhileshiningabrightlightontheoutsideof thelter.Holesinthelterwillappearasbright spots.Ifthelterisdamageddiscardit.
Figure36
1.Aircleanercover
2.Airlter
3.Airlterbody
InstallingtheAirFilter
1.Ifinstallinganewlter,checkthelterforshipping damage.Donotuseadamagedlter.
2.Carefullyslidethelterintothelterbody (Figure36).Ensurethatitisfullyseatedbypushing ontheouterrimofthelterwhileinstallingit.
Important:Donotpressonthesoftinsidearea ofthelter.
3.Installtheaircleanercoverandsecurethelatches (Figure36).
ServicingtheEngineOil
OilType:Detergentoil(APIserviceSF,SG,SHorSJ)
CrankcaseCapacity:withalterchange,68ounces
(2.0L);withoutalterchange,61ounces(1.8L)
Viscosity:Seethetablebelow .
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Figure37
Note:Usingmultigradeoils(5W -20,10W -30,and
10W-40)willincreaseoilconsumption.Checktheoil levelmorefrequentlywhenusingthem.
CheckingtheEngineOilLevel
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
Contactwithhotsurfacesmaycausepersonal injury.
Figure38
1.Mufer3.Rightsidefuelcap
2.Dipstick
6.Pulltheoildipstickandwipethemetalendclean (Figure38).
7.Slidetheoildipstickfullyintotheengine.Pullthe dipstickoutandlookatthemetalend(Figure38).If oillevelislow,slowlypouronlyenoughoilintothe llertubetoraisetheleveltothefullmark.
Important:Donotoverllthecrankcasewith oilbecausetheenginemaybedamaged.Donot runenginewithoilbelowthelowmarkbecause theenginemaybedamaged.
Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasetheseatandtipitforward.
4.Raisetheradiatorcover.
5.Cleanaroundtheoildipstick(Figure38)sodirt cannotfallintoengine.
ChangingtheOil
ServiceInterval:Aftertherst8hours
Every100hours(moreoftenindirty ordustyconditions)
1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.
3.DisengagethePTOandsettheparkingbrake.
4.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
5.Slidethedrainhoseovertheoildrainvalve.
6.Placeapanbelowthedrainhose.Rotateoildrain valvetoallowoiltodrain(Figure39).
7.Whenoilhasdrainedcompletely,closethedrain valve.
8.Removethedrainhose(Figure39).
Note:Disposeoftheusedoilatarecyclingcenter.
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Figure41
1.Engineoillter
3.Applyathincoatofnewoiltotherubbergasketon thereplacementlter(Figure42).
Figure39
1.Oildrainvalve2.Oildrainhose
9.Slowlypourapproximately80%ofthespeciedoil intothellertube(Figure40).
10.Checktheoillevel;refertoCheckingtheEngineOil Level.
11.SlowlyaddtheadditionaloiltobringittotheFull mark.
Figure40
1.Engineoildipstick3.Dipstickend
2.Fillerhole
ChangingtheEngineOilFilter
ServiceInterval:Every200hours
Note:Changetheengineoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.
4.Installthereplacementoilltertothelteradapter. Turntheoillterclockwiseuntiltherubbergasket contactsthelteradapter,thentightenthelteran additional1/2turn(Figure42).
Figure42
1.Oillter
2.Gasket
3.Adapter
5.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.
ServicingtheSparkPlug
Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.
•Type:NGK
®
BPR4ESorequivalent
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Removetheoldlterandwipethelteradapter gasketsurface(Figure41).
•AirGap:0.030inch(0.75mm)
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RemovingtheSparkPlug
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Pullthewire(s)offthesparkplug(s)(Figure43). Nowcleanaroundthesparkplug(s)topreventdirt fromfallingintotheengineandpotentiallycausing damage.
4.Removethesparkplug(s)andmetalwasher.
2.Checkthegapbetweenthecenterandsideelectrodes (Figure44).Bendthesideelectrode(Figure44)if thegapisnotcorrect.
InstallingtheSparkPlug
1.Installthesparkplug(s).Makesuretheairgapisset correctly.
2.Tightenthesparkplug(s)to16ft.-lb(22N⋅m).
3.Pushthewire(s)ontothesparkplug(s)(Figure43).
Figure43
1.Sparkplugwire2.Sparkplug
CheckingtheSparkPlug
ServiceInterval:Every100hours
1.Lookatthecenterofthesparkplug(s)(Figure44). Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly .Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.
Important:Nevercleanthesparkplug(s). Alwaysreplacethesparkplug(s)whenithas:a blackcoating,wornelectrodes,anoilylm,or cracks.
Figure44
1.Canterelectrodeinsulator3.Airgap(nottoscale)
2.Sideelectrode
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FuelSystem Maintenance
ServicingtheElectronicFuel InjectionSystem
Thismachinecontainsanelectronicfuelinjection system.Itcontrolsthefuelowunderdifferent operatingconditions.
CheckingtheMalfunctionIndicator Light
Ifthemalfunctionindicatorlight(MIL)illuminates, duringoperation,theelectroniccontrolunit(ECU)has detectedaproblemorfaultinthedirectfuelinjection (DFI)system.
OncetheMILilluminates,initialtroubleshooting checksshouldbemade.RefertotheMILsectionunder Toubleshooting.
Figure45
1.Fuellter
ServicingtheFuelTank
2.Hydraulictank
Ifthesechecksdonotcorrecttheproblem,further diagnosisandservicingbyanAuthorizedServiceDealer isnecessary.
ServicingtheFuelFilters
ReplacingtheFuelFilter
ServiceInterval:Every400hours/Yearly(whichever
comesrst)(moreoftenindirtyor dustyconditions).
EnsurethatanAuthorizedServiceDealerreplacesthe fuellterandanycomponentsforthefuelsystem.
Useofimpropercomponentscanresultin systemfailure,fuelleakageandpossible explosion.
•EnsurethatanAuthorizedServiceDealer replacethefuellterandanycomponents forthefuelsystem.
Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.
•Useonlyapprovedfuellines,hoseclamps andfuelltersforhighpressuresystems.
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ElectricalSystem Maintenance
ServicingtheBattery
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling .
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.
Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.
•AlwaysDisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
•AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative (black)cable.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchtheseatandtilttheseatup.
4.Firstdisconnectthenegativebatterycablefromthe negative(-)batteryterminal(Figure46).
5.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure46).
RemovingtheBattery
Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery ,do notallowthebatteryterminalstotouchany metalpartsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
Figure46
1.NegativeBatteryPost
2.PositiveBatteryPost
6.Removebothwingnuts(1/4inch)securingthe batteryclamp(Figure47).
7.Removethetwoboltsholdingthehydraulictankin place(Figure47).
8.Slidethehydraulictankawayfromthebattery.
9.Removethebattery.
3.Red(+)cable
4.Black(-)cable
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Figure47
1.Battery4.Wingnut
2.Hydraulictank
3.Bolts
5.Rightsidefueltank
ChargingtheBattery
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).
1.Makesurethellercapsareinstalledinbattery. Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.
2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure48).
3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.
InstallingtheBattery
1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure46).
2.First,installthepositive(red)batterycableto positive(+)batteryterminal.
3.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminal.
4.Securethecableswith2bolts(1/4x3/4inch), 2washers(1/4inch),and2locknuts(1/4inch) (Figure46).
5.Slidetheredterminalbootontothepositive(red) batterypost.
6.SecurebatterywithJ-bolts,holddownclampand 2washers(1/4inch),and2wingnuts(1/4inch) (Figure47).
Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.
Figure48
1.PositiveBatteryPost
2.NegativeBatteryPost
3.Red(+)ChargerLead
4.Black(-)ChargerLead
ServicingtheFuses
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheck component/circuitformalfunctionorshort.
Fuse:
1.Unlatchtheenginehoodandraisetheenginehood togainaccesstofuseholder(Figure49).
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2.Toreplacethefuses,pulloutonthefusetoremove it.
3.Installanewfuse(Figure49).
Figure49
1.RadiatorFan-40amp4.Ignition-30amp
2.Engine-10amp5.Accessory-15amp
3.Clutch-10amp
DriveSystem Maintenance
AdjustingtheTracking
Themachinehasaknobforadjustingthetracking locatedundertheseat.
Important:Adjustthehandleneutralandhydraulic pumpneutralbeforeadjustingthetracking.Refer toAdjustingtheHandleNeutralin,pageand AdjustingtheHydraulicPumpNeutralin,page.
1.Pushbothcontrolleversforwardthesamedistance.
2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.
3.Unlatchtheseatandtilttheseatforwardtoaccess thetrackingknob.
Note:Determinetheleftandrightsidesofthe machinefromthenormaloperatingposition.
4.Tomakethemachinegoright,turntheknobtowards therightsideofthemachine.RefertoFigure50.
5.Tomakethemachinegoleft,turntheknobtowards theleftsideofthemachine.RefertoFigure50.
6.Repeatadjustmentuntilthetrackingiscorrect.
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Figure50
1.Trackingknob4.Turnthiswaytotrackright
2.Hydraulictank
3.Hydraulicpumps
5.Turnthiswaytotrackleft
CheckingtheWheelHub SlottedNut
ServiceInterval:Aftertherst100hours—Checkthe
wheelhubslottednut. Every500hours—Checkthewheel
hubslottednut. Aftertherst100hours—Checkthe
wheellugnuts. Every500hours—Checkthewheel
lugnuts.
Theslottednutneedstobetorquedto125ft-lb (170N-m).
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethecotterpin.
4.Checkthedistancefrombottomofslotinnutto insideedgeofhole.Twothreadsorlessshouldbe showing(Figure52).
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat13psi(90 kPa).Uneventirepressurecancauseunevencut.Check thetireswhentheyarecoldtogetthemostaccurate pressurereading.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
Figure51
Figure52
1.SlottedNut3.Holeinthreadedshaft
2.Twothreadsorless showing
4.Washer(ifneeded)
5.Ifmorethantwothreadsareshowingremovenut andinstallwasherbetweenhubandnut.
6.Torquetheslottednutto125ft-lb.(170N-m) (Figure52).
7.Tightenthenutuntilthenextsetofslotslineupwith theholeintheshaft(Figure52).
8.Replacethecotterpin.
AdjustingtheCasterPivot Bearing
ServiceInterval:Every500hours/Yearly(whichever
comesrst)
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1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethedustcapfromcasterandtightenlock nut(Figure53).
4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(Figure53).
Important:Makesurespringwashersare installedcorrectlyasshowninFigure53.
5.Installthedustcap(Figure53).
6.Removetherightrearwheelfromthemachine.
7.Locatetheholeintheframeandremovetheside pluginthegearbox.(Figure54).
8.Theoilneedsbeuptotheopeningofthegearbox hole.
9.Addoilifneededtobringittothecorrectlevel.
Figure54
1.Rightrearwheel3.Jackstand
2.Lugnuts
4.Holeinthesideofframe toaccessthesideplug
Figure53
1.SpringWashers3.DustCap
2.LockNut
ServicingtheGearBox
CheckingtheGearBoxOilLevel
ServiceInterval:Every100hours
Yearly
UseSAE75W–90SyntheticGearLube.
1.Parkthemachineonalevelsurface.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Loosenthelugnutsontherightrearwheel.
5.Raiserearofthemachinesotherightrearwheelis offthegroundandsupportthemachinewithjack stands.
ChangingtheGearBoxOil
ServiceInterval:Aftertherst100hours
ContactanAuthorizedServiceDealertochangethe gearboxoil.
AdjustingtheElectricClutch
ServiceInterval:Every500hours
Theclutchisadjustabletoensureproperengagement andproperbraking.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchtheseatandtipitforward.
4.Loosenthefrontenginepanelknobsandremove thepanel.
5.Pushdownonthespringloadedidlerpulleyforthe PTOdrivebeltandremovethebeltfromtheclutch pulley(Figure55).
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11.Repeatthisfortheremainingslots.
12.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.
Figure55
1.PTOdrivebelt3.Springloadedidlerpulley
2.Gearbox
6.Unplugtheelectricconnectionfortheclutch (Figure56).
7.Removethetwoboltsholdingtherubberclutch straptothemowerframe(Figure56).
8.Removethecenterboltholdingtheclutchto theengineshaftandremovetheclutchandkey (Figure56).
Figure57
1.Slot
2.Adjustingnut
3.Feelergauge
13.Installtheclutchtotheengineshaftwiththekey.
14.ApplyblueLoctite®(orequivalent)tothecenter bolt.
15.Whileholdingthecrankshaftatthebackofthe machine,installthecenterboltandtorqueitto50 ft-lbs(68N-m)(Figure56).
16.Installtherubberclutchstraptothemowerframe withthetwopreviouslyremovedboltsandnuts (Figure56).
17.Pushdownonthespringloadedidlerforthe PTOdrivebeltandinstallitontotheclutchpulley (Figure55).
18.Plugintheelectricconnectionfortheclutch (Figure56).
Figure56
1.Clutch4.Clutchcenterbolt
2.Twoboltsandnutsfor clutchstrap
3.Rubberclutchstrap
5.Electricalconnection
9.Inserta0.015–0.021inch(0.381–0.533mm)feeler gaugethroughoneinspectionslotinthesideofthe assembly.Makesureitisbetweenthearmatureand therotorfrictionsurfaces(Figure57).
10.Tightenthelocknutsuntilthereisslightbindingon thefeelergaugebutitcanbemovedeasilywithinthe airgap(Figure57).
19.Installthefrontenginepanelandtightentheknobs.
20.Lowerdowntheseat.
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CoolingSystem Maintenance
ServicingtheCoolingSystem
Dischargeofhotpressurizedcoolantor touchinghotradiatorandsurroundingparts cancausesevereburns.
•Donotremovetheradiatorcapwhenthe engineishot.Alwaysallowtheengineto coolatleast15minutesoruntiltheradiator capiscoolenoughtotouchwithoutburning yourhandbeforeremovingtheradiatorcap.
•Donottouchradiatorandsurroundingparts thatarehot.
1.Positionthemachineonalevelsurface,stopthe engine,andsettheparkingbrake.
2.Withtheenginecool,checktheoverowbottlelevel. Theuidneedstobeuptothebumpontheoutside oftheoverowbottle(Figure58).
3.Ifthecoolantlevelislow,adda50/50mixof extendedlifeantifreeze/Dex-Cool®andwaterto theoverowbottle(Figure58).
4.Addthe50/50coolantmixtotheoverow bottleandllittotheindicatorlineonthebottle (Figure58).
Rotatingshaftandfancancausepersonal injury.
•Donotoperatethemachinewithoutthe coversinplace.
•Keepngers,handsandclothingclearof rotatingfananddriveshaft.
•Shutofftheengineandremovetheignition keybeforeperformingmaintenance.
Swallowingenginecoolantcancausepoisoning.
•Donotswallowenginecoolant.
•Keepoutofreachfromchildrenandpets.
CheckingtheRadiatorCoolant
ServiceInterval:Beforeeachuseordaily
Aftertherst8hours
Figure58
1.Antifreezeoverowbottle2.Indicatorlineonsideof overowbottle
ChangingtheEngineCoolant
ServiceInterval:Yearly
Changetheenginecoolantyearly .
ContactanAuthorizedServiceDealerforchangingthe coolant.
CleaningtheHydraulicOilCoolerand RadiatorScreen
ServiceInterval:Beforeeachuseordaily
Every100hours
FluidType:50/50mixofextendedlife antifreeze/Dex-Cool®andwater
CoolingSystemCapacity:156ounces(4.6l)
Note:Donotopentheradiatorcap.Doingthismay induceairintothecoolingsystem.
Beforeeachuse,checkandcleantheradiatorscreen andoilcooler.Removeanybuild-upofgrass,dirtor otherdebrisfromtheoilcoolerandradiatorscreenwith compressedair(Figure59).
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Figure59
1.Hydraulicoilcooler2.Radiator
BrakeMaintenance
AdjustingtheParkingBrake
ServiceInterval:Every200hours—Checktheparking
brakeadjustment.
1.Engagetheparkingbrake,leverup.
2.Measurethelengthofthespring.Measurement shouldbe2-1/2inch(64mm)betweenthewashers (Figure60).
3.Ifadjustmentisnecessary,releasetheparkingbrake, loosenthejamnutbelowthespringandadjustthe nutdirectlybelowthespring(Figure60).Turnthe nutuntilthecorrectmeasurementisobtained.Turn thenutclockwisetoshortenspringlengthandturn counter-clockwisetolengthenthespring.
4.Tightenthetwonutstogether.
5.Engagetheparkingbrake,leverup.Checkthe measurementofthespringagain.
6.Ifadjustmentisnecessary,repeattheprocedures above.
7.Repeatontheoppositesideofmachine.
Figure60
1.Brakeleverinengaged position
2.Spring2–1/2inch(64mm)
3.Adjustingnutandjamnut
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BeltMaintenance
InspectingtheBelts
ServiceInterval:Every100hours
Checkthebeltsforsquealingwhenthebeltisrotating, bladesslippingwhencuttinggrass,frayedbeltedges, burnmarksandcracksaresignsofawornmowerbelt. Replacethemowerbeltifanyoftheseconditionsare evident.
ReplacingtheMowerBelt
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofawornmowerbelt.Replacethemowerbelt ifanyoftheseconditionsareevident.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
8.Installthenewbeltaroundthemowerpulleysand thegearboxpulleyundertheengine(Figure62).
Figure62
1.Mowerbelt
2.Mowerspindlepulley6.Idlerspring
3.Springloadedidlerpulley7.Idlerplate(for72inch
4.Beltguideata45degree angle
5.Gearboxpulley
mowersonly)
3.Removethebeltcovers(Figure61).
Figure61
1.Beltcover3.Insertslotintothetab
2.Latch
4.For72inchmowers,loosentheidlerplatebolts holdingtheidlerplate(Figure64).
9.Installthebeltguideonthespringloadedidlerata 45degreeangleasshowninFigure62andFigure64. Torquetheboltto27to33ft-lb(37to45N-m).
10.Installtheidlerspringtothetwoposts(Figure62 andFigure64).
11.For72inchmowers,adjustthebelttension,referto AdjustingtheMowerBeltTension.
12.Installthebeltcoversbyslidingthecoverintothe tab,installthebolts,andclosethelatches(Figure63).
5.Removetheidlerspring.
6.Removethebeltguideonthespringloadedidler pulleyshowninFigure62andFigure64.
7.Removetheexistingbelt.
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Figure63
1.Beltcover3.Insertslotintothetab
2.Latch
AdjustingtheMowerBelt
1.Beltguideinstallata45 degreeangle
2.Idlerspringlength (between10and10-1/4 inches(25.4and26.0cm))
3.Idlerplate
Figure64
4.Ratchetorbreakerbar
5.Idlerplatebolt
Tensionfor72inMowersOnly
ServiceInterval:Aftertherst8hours
Important:T oensurepropermowerbelttension, whichwillresultinalongerbeltlife,checkthe mowerbelttensionaftertherst8hoursofuseand 8hoursaftereachbeltchange.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Adjustthemowerdecktothe3inch(76mm) height-of-cutposition.
4.Measurethespringlength(Figure64).Ifthespring lengthisbetween10and10-1/4inches(25.4and
26.0cm),fromposttopost,noadjustmentisneeded.
5.Loosentheboltsholdingtheidlerplate(Figure64).
6.Insertaratchetorbreakerbarintothesquareholein theidlerplatetoadjustthetension(Figure64).
ReplacingthePTODriveBelt
ServiceInterval:Every50hours—CheckthePTO
drivebelt.
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofawornPTObelt.Replacethemowerbeltif anyoftheseconditionsareevident.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosenthefrontenginepanelknobsandremove thepanel(Figure65).
7.Rotatetheratchetorbreakerbartomovetheidler plateuntiltheidlerspringisbetween10and10-1/4 inches(25.4and26.0cm)fromposttopostas showninFigure64.
8.Whileholdingthebelttensionandspringlength, tightentheidlerplateboltsthatsecuretheidlerplate (Figure64).
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ReplacingthePumpDriveBelt
ServiceInterval:Every50hours—Checkthepump
drivebelt.
Note:RemovethePTOdrivebeltrstifthepump drivebeltneedstobereplaced.RefertoReplacingthe PTODriveBelt.
1.Tilttheseatforwardandremovethefrontengine panel.
2.RemovethePTOdrivebelt.
3.Removethespringfromtheidlerarm(Figure67).
4.Installthenewbeltaroundtheengineandhydraulic pumppulley(Figure67).
5.InstallthePTOdrivebelt.
Figure65
1.Knob2.Frontenginepanel
4.Removethespringfromtheidlerarm(Figure66).
5.Removetheclutchstopstrap.
6.RemovetheoldPTOdrivebelt.
7.InstallthePTOdrivebeltaroundtheclutchpulley andthegearboxpulley(Figure66).
8.Installtheclutchstopstrap.
9.Installthespringtotheidlerarm(Figure66).
6.Installthespringtotheidlerarm(Figure67).
Figure67
1.Clutch
2.Springloadedidlerpulley4.Spring
3.Pumpdrivebelt
Figure66
1.PTODrivebelt4.Clutch
2.Gearbox5.Springloadedidlerpulley
3.Spring
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ControlsSystem Maintenance
9.Applyslightrearwardpressureonthemotion controllever,turntheheadoftheadjustmentbolt intheappropriatedirectionuntilthecontrolleveris centeredintheneutrallockposition(Figure69).
AdjustingtheControlHandle NeutralPosition
Ifmotioncontrolleversdonotalign,ormoveeasilyinto theconsolenotch,adjustmentisrequired.Adjusteach lever,springandrodseparately.
Note:Motioncontrolleversmustbeinstalledcorrectly. SeeInstallingtheMotionControlLeversinthesetup instructions.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchtheseatandtilttheseatforward.
4.Beginwitheithertheleftorrightmotioncontrol lever.
5.Movethelevertotheneutralpositionbutnotlocked (Figure68).
Note:Keepingrearwardpressureontheleverwill keepthepinattheendoftheslotandallowthe adjustmentbolttomovethelevertotheappropriate position.
10.Tightenthenutandjamnut(Figure69).
11.Repeatfortheoppositesideofthemachine.
6.Pulltheleverbackuntiltheclevispin(onarm belowpivotshaft)contactstheendoftheslot(just beginningtoputpressureonthespring)(Figure68).
7.Checkwherethecontrolleverisrelativetonotchin console(Figure68).Itshouldbecenteredallowing levertopivotoutwardtotheneutrallockposition.
Figure68
1.Neutrallockedposition3.Neutralposition
2.Controllever
Figure69
1.Height-of-cutlever
2.Nutagainstyoke6.Yoke
3.JamNut
4.Clevispininslot
5.Adjustmentbolt
7.Spring
8.Ifadjustmentisneeded,loosenthenutandjamnut againsttheyoke(Figure69).
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HydraulicSystem Maintenance
ServicingtheHydraulic System
FluidType:Mobil115W -50syntheticmotoroilor equivalentsyntheticoil.
Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.
HydraulicSystemOilCapacity:132ounces(3.9l)
CheckingtheHydraulicFluid
Figure70
1.Cap3.Colduidlevel-full
2.Bafe4.Hotuidlevel-full
ServiceInterval:Aftertherst8hours—Checkthe
hydraulicuid.
Every25hours—Checkthehydraulic uid.
Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoilis cold.Thebafeinsidethetankhastwolevelsdepending iftheoiliswarmorcold.
1.Positionthemachineonalevelsurfaceandsetthe parkingbrake.
2.Cleantheareaaroundllerneckofhydraulictank (Figure70).
3.Removethecapfromthellerneck.Lookinsideto checkifthereisuidinthereservoir(Figure70).
4.Ifthereisnouid,adduidtothereservoiruntilit reachesthecoldlevelofthebafe.
5.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmtheuid. RefertoStartingandStoppingtheEnginein,page.
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
•Usecardboardorpapertondhydraulic leaks.
•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
6.Rechecktheuidlevelwhiletheuidiswarm.The uidshouldbebetweencoldandhot.
7.Ifrequired,adduidtothehydraulictank.
Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidishot(Figure70).
8.Installcaponllerneck.
ReplacingtheHydraulicFilterandOil
ServiceInterval:Aftertherst25hours
Yearly
Usesummerlterabove32degreesF(0degreesC)
Usewinterlterbelow32degreesF(0degreesC)
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
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Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.
3.Placedrainpanunderlter,removetheoldlter andwipethelteradaptergasketsurfaceclean (Figure71).
Figure71
1.Hydrauliclter
4.Removetherighthandhydrauliclinethatcomesinto theadapter(Figure72).
5.Allowtheoiltodrainoutofthesystemintothe drainpan.
6.Installtherighthandhydrauliclinetotheadapter (Figure72).
12.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.
13.Rechecktheuidlevelwhiletheuidiswarm.The uidshouldbebetweencoldandhot.
14.Ifrequired,adduidtothehydraulictank.Donot overll.
Figure73
1.Hydrauliclter
2.Gasket
3.Adapter
Figure72
1.Righthandhydraulicline3.Hydraulictank
2.Hydrauliclter
7.Applyathincoattotherubbergasketonthe replacementlter(Figure73).
8.Installthereplacementhydrauliclterontothelter adapter.Donottighten.
9.Fillthehydraulictankwithhydraulicuiduntilthe uidoverowsthelterandthenturntheoillter clockwiseuntiltherubbergasketcontactsthelter adapter,thentightenthelteranadditional1/2turn (Figure73).
10.Cleanupanyspilleduid.
11.Adduidtothecoldlevelofthebafeinthe hydraulictank.
BleedingtheHydraulicSystem
Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemifuidischangedorafter workisperformedonthesystem.
1.Raiserearofthemachinesowheelsareoffthe groundandsupportwithjackstands.
2.Starttheengineandrunatlowidlespeed.Engage theleverandtractionononesideandspinthewheel byhand.
3.Whenthewheelbeginstospinonitsown,keepit engageduntilwheeldrivessmoothly .(minimum 2minutes)
4.Checkhydraulicuidlevelandaddasrequiredto maintainproperlevel.
5.Repeatthisprocedureontheoppositewheel.
CheckingtheHydraulicHoses
ServiceInterval:Every100hours
Checkthehydraulichosesforleaks,loosettings, kinkedlines,loosemountingsupports,wear,weather andchemicaldeterioration.Makenecessaryrepairs beforeoperating.
Note:Keepareasaroundthehydraulicsystemclean fromgrassanddebrisbuildup.
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1.Raisetheframeandblockupthemachinesodrive wheelscanrotatefreely .
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
•Usecardboardorpapertondhydraulic leaks.
•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
2.Disconnecttheelectricalconnectorfromtheseat safetyswitch.Temporarilyinstallajumperwire acrossterminalsinthewiringharnessconnector.
3.Unlatchtheseatandslideseatforward.
4.Disconnecttheseatrodandtilttheseatfullyforward.
SettingtheRight-handHydraulicPump NeutralPosition
1.Starttheengine,openthethrottle1/2wayand releaseparkingbrake.RefertoStartingandStopping theEnginein,page.
Note:Themotioncontrollevermustbeinneutral whilemakinganyadjustments.
2.Adjustthepumprodlengthbyrotatingtheknob,in theappropriatedirection,untilthewheelisstillor slightlycreepinginreverse(Figure74).
3.Movethemotioncontrolleverforwardandreverse, thenbacktoneutral.Thewheelmuststopturning orslightlycreepinreverse.
SettingtheHydraulicPump NeutralPosition
Note:Adjustthehandleneutralrst.Thatneedstobe
correctbeforethefollowingadjustmentcanbemade.
Thisadjustmentmustbemadewithdrivewheelsturning.
Mechanicalorhydraulicjacksmayfailto supportmachineandcauseaseriousinjury .
•Usejackstandwhensupportingmachine.
•Donotusehydraulicjacks.
Enginemustberunningsomotioncontrol adjustmentcanbeperformed.Contactwith movingpartsorhotsurfacesmaycause personalinjury.
4.Openthethrottletofast.Makesurewheelremains stoppedorslightlycreepsinreverse,adjustif necessary.
Keephands,feet,face,clothingandotherbody partsawayfromrotatingparts,muferand otherhotsurfaces.
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Figure74
1.Trackingknob4.Turnthiswaytotrackright
2.Hydraulictank
3.Hydraulicpumps
5.Turnthiswaytotrackleft
Figure75
1.Doublenuts4.Locknut
2.Pumprod5.Balljoint
3.Adjustmentbolt6.Pumps
SettingtheLeft-handHydraulicPump NeutralPosition
1.Loosenthelocknutsattheballjointsonthepump controlrod(Figure75).
2.Starttheengine,openthrottle1/2wayandrelease parkingbrake.RefertoStartingandStoppingthe Enginein,page.
Note:Themotioncontrollevermustbeinneutral whilemakinganyadjustments.
Note:Thefrontnutonthepumprodhasleft-hand threads.
3.Adjustthepumprodlengthbyrotatingdoublenuts onrod,intheappropriatedirection,untilwheelis stillorslightlycreepsinreverse(Figure75).
4.Movethemotioncontrolleverforwardandreverse, thenbacktoneutral.Thewheelmuststopturning orslightlycreepinreverse.
5.Openthethrottletofast.Makesurethewheel remainsstoppedorslightlycreepsinreverse,adjust ifnecessary.
Electricalsystemwillnotperformpropersafety shutoffwithjumperwireinstalled.
•Removejumperwirefromwireharness connectorandplugconnectorintoseat switchwhenadjustmentiscompleted.
•Neveroperatethisunitwithjumperinstalled andseatswitchbypassed.
7.Afterbothpumpneutralsareset,shutoffthe machine.
8.Removethejumperwirefromthewireharness connectorandplugtheconnectorintotheseat switch.
9.Installtheseatrodandlowertheseatintoposition.
10.Removethejackstands.
6.Tightenthelocknutsattheballjoints(Figure75).
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MowerDeck Maintenance
LevelingtheMoweratThree Positions
Important:Thereareonlythreemeasuring
positionsneededtolevelthemower.
SettingUptheMachine
1.Positionmoweronaatsurface.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
1.Measureherefromblade tohardsurface
Figure76
2.MeasureatBandC
3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Checktirepressureofallfourtires.Ifneeded,adjust to13psi(90kPa)
5.Lowerthemowertothe3inch(76mm)height-of-cut position.
6.Inspectthefourchains.Thechainsneedtohave tension.
Note:Adjusttherearchainstothetopoftheslot, wheretheyareattachedtothemower.
•Ifonerearchainisloose,lower(loosen)thefront supportarmonthesameside.RefertoAdjusting theFront-to-RearMowerPitch.
•Ifonefrontchainisloose,raise(tighten)the frontsupportarmforthatchain.Referto AdjustingtheFront-to-RearMowerPitch.
LevelingtheMowerSide-to-Side
2.MeasuretherightbladeattheBlocation,froma levelsurfacetothecuttingedgeofthebladetip (Figure76).
3.Recordthismeasurement.Thismeasurementneeds tobe3-1/8to3-1/4inches.
4.Positiontheleftbladeside-to-side(Figure76).
5.MeasuretheleftbladeattheClocation(Figure76), fromalevelsurfacetothecuttingedgeoftheblade tip.
6.Recordthismeasurement.Thismeasurementneeds tobe3-1/8to3-1/4inches(80to83mm).
7.IfthemeasurementsatpositionsBorCarenot correct,loosentheboltattachingtherearchainto therearsupportarm(Figure77).
1.Positiontherightbladeside-to-side(Figure76).
Figure77
1.Rearchain5.Adjustmentbolt
2.Rearsupportarm6.Frontswivel
3.Bolt7.Frontsupportarm
4.JamNut
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8.Loosenthejamnutundertherearsupportarmand adjusttheadjustmentbolttogetameasurementof 3-1/8to3-1/4inches(80to83mm)(Figure77).
Note:Itisrecommendedthatbothsidesofthe mowerareadjustedthesamedistance.
9.Tightenthejamnutundertherearsupportarm andtightentheboltsecuringthechaintotherear supportarm.
10.Adjusttheoppositesideifneeded.
8.Adjusttheliftnutsonboththeleftandtheright sideofthemachinetoachieve1/4to3/8inch (6to10mm)lowerinfrontatAthanintherearat B(Figure77).
9.Tightenbothswiveljamnutsagainstthefrontswivel tolocktheheight.
10.Checktomakesurethereisequaltensiononthe chainsandadjustagainifneeded.
AdjustingtheCompressionSpring
AdjustingtheFront-to-RearMower Pitch
1.Positiontherightbladefront-to-rear(Figure78).
Figure78
1.Measureherefromblade tohardsurface
2.MeasureatAandB
1.Raisethemowerliftlevertothetransportposition.
2.Checkthedistancebetweenthetwolargewashers, itneedstobe10-1/2inches(26.7cm)for60inch mowerdecksor11–1/2inches(29.2cm)for72inch mowerdecks(Figure79).
3.Adjustthisdistance,bylooseningthespringjam nutandturningthenutinfrontofeachspring (Figure79).Turningthenutclockwisewillshorten thespring;counter-clockwisewilllengthenthe spring.
4.Lockthenutintopositionbytighteningthespring jamnut(Figure79).
2.MeasuretherightbladeattheAlocation,froma levelsurfacetothecuttingedgeofthebladetip (Figure78).
3.Recordthismeasurement.
4.MeasuretherightbladeattheBlocation,froma levelsurfacetothecuttingedgeofthebladetip (Figure78).
5.Recordthismeasurement.
6.Themowerbladeshouldbea1/4to3/8inch (6to10mm)loweratpositionAthanatposition B(Figure78).Ifitisnotcorrect,proceedtothe followingsteps.
Note:Bothofthefrontswivelsneedtobeadjusted thesameamounttomaintainequalchaintension.
7.Loosenthefrontswiveljamnuts,atthefrontof therightandleftswivels,approximatelya1/2inch (13mm)(Figure77).
Figure79
1.10-1/2inch(26.7cm) betweenthelargewashers for60inchmowerdecks
2.Frontnut7.Frontsupportarm
3.Springjamnut
4.Frontswivel
5.Swiveljamnut
55
6.Liftnut
8.Largewasher
9.11–1/2inch(29.2cm) betweenthelargewashers for72inchmowerdecks
Page 56
ServicingtheCuttingBlades
Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.
Checkthecutterbladesdailyforsharpness,andforany wearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn, replaceitimmediatelywithagenuineTororeplacement blade.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
Awornordamagedbladecanbreak,anda pieceofthebladecouldbethrownintothe operator’sorbystander’sarea,resultingin seriouspersonalinjuryordeath.
•Inspectthebladeperiodicallyforwearor damage.
•Replaceawornordamagedblade.
Figure80
1.CuttingEdge3.Wear/slotForming
2.CurvedArea4.Crack
CheckingforBentBlades
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure81).Measurefromalevelsurface tothecuttingedge,positionA,oftheblades (Figure81).Notethisdimension.
BeforeInspectingorServicingthe Blades
Parkthemachineonalevelsurface,disengagetheblade control(PTO),andsettheparkingbrake.Turnthe ignitionkeytoOff.Removethekey .
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure80).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
2.Inspecttheblades,especiallythecurvedarea (Figure80).Ifyounoticeanydamage,wear,oraslot forminginthisarea(Figure80),immediatelyinstalla newblade.
Figure81
1.Measureherefromblade tohardsurface
2.PositionA
4.Rotatetheoppositeendsofthebladesforward.
5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).If thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.
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Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedbladewith anewblade.
•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
RemovingtheBlades
Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum performanceandcontinuedsafetyconformanceof themachine,usegenuineTOROreplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
Contactwithasharpbladecancauseserious injury.
Wearglovesorwrapsharpedgesoftheblade witharag.
Figure82
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure83).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure84).Repeatthis procedureuntilthebladeisbalanced.
Figure83
1.Blade2.Balancer
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure84).
1.Holdthebladeendusingaragorthickly-padded glove.
2.Removethebladebolt,springdiskandbladefrom thespindleshaft(Figure84).
SharpeningtheBlades
Whensharpeningblade,piecesofbladecould bethrownandcauseseriousinjury.
Wearpropereyeprotectionwhensharpening blade.
1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure82).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead (Figure84).Torquethebladeboltto85-110ft-lb (115-150N-m).
Figure84
1.SailAreaofBlade
2.Blade
3.SpringDisk
4.BladeBolt
5.ConeTowardsBoltHead
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ReplacingtheGrassDeector
Anuncovereddischargeopeningcouldallow thelawnmowertothrowobjectsinthe operator’sorbystander’sdirectionandresult inseriousinjury.Also,contactwiththeblade couldoccur.
Cleaning
CleaningUndertheMower
ServiceInterval:Beforeeachuseordaily
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
•Neveroperatethelawnmowerunlessyou installacoverplate,amulchplate,oragrass chuteandcatcher.
•Makesurethegrassdeectorisinthedown position.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure85). Removethedamagedorworngrassdeector.
2.Placethespacerandspringontograssdeector. PlacetheLendofspringbehinddeckedge.
Note:MakesuretheLendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure85.
3.Installtheboltandnut.PlacetheJhookendofthe springaroundthegrassdeector(Figure85).
Important:Thegrassdeectormustbeableto lowerdownintoposition.Liftthedeectorup totestthatitlowersintothefulldownposition.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethemowertothetransportposition.
WasteDisposal
Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.
Figure85
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring8.Jhookendofspring
5.Springinstalled
7.Lendofspring,place behinddeckedgebefore installingbolt
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Storage
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
CleaningandStorage
1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytoOff.Removethe key.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engineandhydraulicsystem.Cleandirtandchaff fromtheoutsideoftheenginecylinderheadnsand blowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuseof water,especiallynearthecontrolpanel,engine, hydraulicpumps,andmotors.
3.Checkthebrake;refertoServicingtheBrakein, page.
4.Servicetheaircleaner;refertoServicingtheAir Cleanerin,page.
5.Greasethemachine;refertoGreasingand Lubricationin,page.
C.Stoptheengine,allowittocool,anddrainthe
fueltank;refertoServicingtheFuelTankin, page.
D.Restarttheengineandrunituntilitstops.
E.Disposeoffuelproperly.Recycleasperlocal
codes.
Important:Donotstore stabilizer/conditionedfuelover90days.
13.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.
14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
15.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitoutofreachofchildrenorotherunauthorized users.Coverthemachinetoprotectitandkeepit clean.
6.Changethecrankcaseoil;refertoServicingthe EngineOilin,page.
7.Checkthetirepressure;refertoCheckingtheTire Pressurein,page.
8.Changethehydrauliclter;refertoServicingthe HydraulicSystemin,page.
9.Chargethebattery;refertoServicingtheBatteryin, page.
10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.
Note:RunthemachinewiththePTOengaged andtheengineathighidlefor2to5minutesafter washing.
11.Checktheconditionoftheblades;refertoServicing theCuttingBladesin,page.
12.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachineforstorage asfollows:
A.Addapetroleumbasedstabilizer/conditioner
tofuelinthetank.Followmixinginstructions fromthestabilizermanufacturer.Donotusean alcoholbasedstabilizer(ethanolormethanol).
Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshfuelandused atalltimes.
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Troubleshooting
Problem
Starterdoesnotcrank
Enginewillnotstart,startshard,orfails tokeeprunning.
PossibleCauseCorrectiveAction
1.Bladecontrol(PTO)isengaged.1.Movebladecontro(PTO)to
2.Parkingbrakeisnoton.
3.Operatorisnotseated.3.Sitontheseat.
4.Batteryisdead.
5.Electricalconnectionsarecorrodedor loose.
6.Fuseisblown.
7.Relayorswitchisdefective.7.ContactanAuthorizedServiceDealer.
1.Fueltankisempty.
2.Thefuelshut-offvalveisnotopen completely.
3.Engineistoohot.
4.Aircleanerisdirty.
5.Incorrectfuelltersusedordirtyfuel lters.
6.Dirt,water ,orstalefuelisinthefuel system.
7.Oldgasinthegastank.
8.Fueltankventcapisblocked.
disengaged.
2.Settheparkingbrake.
4.Chargethebattery.
5.Checktheelectricalconnectionsfor goodcontact.
6.Replacefuse.
1.Fillfueltankwithfuel.
2.Openthefuelshut-offvalve.
3.Turnengineoffandletitcool.
4.Cleanorreplacetheaircleaner element.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
7.Usenewgas.
8.Makesurethatthefueltankventcapis notblockedandworkingproperly.
Enginelosespower.
Engineoverheats.
Machinedoesnotdrive.
Abnormalvibration.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesabove theengineareplugged.
5.Ventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.
6.Dirtinthefuellter.6.Replacethefuellter.
7.Dirt,water ,orstalefuelisinthefuel system.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesabove theengineareplugged.
1.Bypassvalveisnotclosedtight.1.Tightenthebypassvalve.
2.Driveorpumpbeltisworn,looseor broken.
3.Driveorpumpbeltisoffapulley.3.Changethebelt.
4.Brokenormissingidlerspring.4.Replacethespring.
5.Hydraulicuidlevelislowortoohot.5.Addhydraulicuidtoreservoirorletit
1.Cuttingblade(s)is/arebentor unbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley,idlerpulley,or bladepulley .
5.Enginepulleyisdamaged.
6.Bladespindleisbent.
7.Motormountislooseorworn.
2.Cleantheaircleanerelement.
3.Addoiltothecrankcase.
4.Removetheobstructionfromthe coolingnsandairpassages.
7.ContactanAuthorizedServiceDealer.
2.Addoiltothecrankcase.
3.Removetheobstructionfromthe coolingnsandairpassages.
2.Changethebelt.
cooldown.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley .
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
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Problem
PossibleCauseCorrectiveAction
Unevencuttingheight.
Bladesdonotrotate.
MalfunctionIndicatorLight(MIL)comes on.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerisnotlevel.
4.Undersideofmowerisdirty.4.Cleantheundersideofthemower.
5.Tirepressureisnotcorrect.5.Adjustthetirepressure.
6.Bladespindlebent.
1.Drivebeltisworn,looseorbroken.
2.Drivebeltisoffpulley .
3.Deckbeltisworn,looseorbroken.3.Installnewdeckbelt.
4.Deckbeltisoffpulley .
5.Brokenormissingidlerspring.5.Replacethespring.
1.Engineistoohot.
2.Oldgasinthegastank.
3.Thefuelshut-offvalveisnotopen completely.
4.Fueltankventcapisblocked.
5.Aircleanerisdirty.5.Makesurethattheaircleanerand
6.Batteryisnotcharged.
7.Incorrectfuelltersusedordirtyfuel lters.
8.Connectionstosensorselectronic controlunit(ECU)andfuelinjectors arenotsecuredproperly.
3.Levelmowerfromside-to-sideand front-to-rear.
6.ContactanAuthorizedServiceDealer.
1.Checkthebelttension.
2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.
4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.
1.Turnengineoffandletitcool.
2.Usenewgas.
3.Openthefuelshut-offvalve.
4.Makesurethatthefueltankventcapis notblockedandworkingproperly.
precleanerareclean.Replaceif necessary.
6.Chargeorreplacethebattery.
7.ContactanAuthorizedServiceDealer.
8.ContactanAuthorizedServiceDealer.
61
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Schematics
WireDiagram(Rev.B)
62
Page 63
Notes:
63
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The Toro Total Coverage Guarantee
A Limited Warranty (see warranty periods below)
Landscape
Contractor
Equipment (LCE)
The Toro Company and its affiliate, Toro Warranty Company, pursuant to an
Conditions and Products Covered
agreement between them, jointly promise to repair the listed Toro Products if defective in materials or workmanship.
The following warranty time periods apply from the date of purchase by the original owner:
Product Warranty Period
Mid-Size Walk-Behind Mowers 2 years** GrandStand
•
•
Z Master
•
•
Z Master® G3 Mowers
•
•
Batteries (for above units)
TM
Mowers Engine Frame
®
Z300, Z400, Z500 Mowers Engine Frames
Engine Frame
5 years or 1,200 hours* 2 years** Lifetime (original owner only)***
4 years or 1,200 hours* 2 years** Lifetime (original owner only)***
5 years or 1,200 hours* 2 years** Lifetime (original owner only)***
1 year
Attachments (for above units) 1 year
*Whichever occurs fi rst. **Some engines used on Toro LCE Products are warranted by the engine manufacturer. ***Lifetime Frame Warranty - If the main frame, consisting of the parts welded together to form the tractor structure that other components such as the engine are secured to, cracks or breaks in normal use, it will be repaired or replaced under warranty at no cost for parts and labor. Frame failure due to misuse or abuse and failure or repair required due to rust or corrosion are not covered.
This warranty includes the cost of parts and labor, but you must pay transportation costs.
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 Authorized Toro Service Dealer to arrange service at their dealership. To locate a dealer convenient to you, refer to the Yellow Pages of your telephone directory (look under “Lawn Mowers”) or access our web site at www.Toro.com. You may also call the numbers listed in item #3 to use the 24-hour Toro Dealer locator system.
2. Bring the product and your proof of purchase (sales receipt) to the Service Dealer. The dealer will diagnose the problem and determine if it is covered under warranty.
3. If for any reason you are dissatisfi ed 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 888-865-5676 (U.S. Customers) 888-865-5691 (Canada customers)
You must maintain your Toro Product by following the maintenance
Owner Responsibilities
procedures described in the Operator’s Manual. Such routine maintenance, whether performed by a dealer or by you, is at your expense.
Items and Conditions Not Covered
There is no other express warranty except for special emission system and engine warranty coverage on some products. This express warranty does not cover:
Cost of regular maintenance service or parts, such as fi lters, 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 non­use over three months.
Pickup and delivery charges.
•
General Conditions
All repairs covered by this warranty must be performed by an Authorized Toro Service Dealer using Toro approved replacement parts.
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.
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.
Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.
This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.
Customers who have purchased Toro products outside the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee
Countries Other than the United States or Canada
policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi culty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.
Part Number 374-0037 Rev. H
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