Toro 74265TE Operator's Manual

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Page 1

Form No. 3356-310 Rev A

Z593-D Z Master® with 52in or 60in TURBO FORCE® Side Discharge Mower

Model No. 74264TE —Serial No. 270000001 and Up Model No. 74265TE —Serial No. 270000001 and Up

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T his spark ignition system complies with Canadian ICES-002

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Riding Mo w er Safety . . . . . . . . . . . . . . . . . . . 5

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Sound P o w er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Slope Char t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chec king the Engine Oil Lev el . . . . . . . . . . . 17

Switc hing the Fuel T anks . . . . . . . . . . . . . . . . . . . 17

Using the R ollo v er Protection

System (R OPS) . . . . . . . . . . . . . . . . . . 17

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operating the P arking Brak e . . . . . . . . . . . . . . 19

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operating the P o w er T ak e Off

(PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

T he Safety Interloc k System . . . . . . . . . . . . . . . 22

Dri ving F orw ard or Bac kw ard . . . . . . . . . . . . 22

Stopping the Mac hine . . . . . . . . . . . . . . . . . . . . . . . . 23

Adjusting the Height-of-Cut . . . . . . . . . . . . . . 23

Adjusting the Anti-Scalp

R ollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Adjusting the Flo w Bafﬂe . . . . . . . . . . . . . . . . . . . 25

P ositioning the Flo w Bafﬂe . . . . . . . . . . . . . . . . 25

P ositioning the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unlatc hing the Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pushing the Mac hine b y Hand . . . . . . . . . . . . 27

Using the Side Disc harg e . . . . . . . . . . . . . . . . . . . 27

T ranspor ting Mac hines . . . . . . . . . . . . . . . . . . . . . . 28

Loading Mac hines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

Greasing the Mo w er Dec k and Belt

Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 33

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 34

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Ser vicing the Fuel Filters . . . . . . . . . . . . . . . . . . . . 38

Ser vicing the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . 38

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 38

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Ser vicing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the T rac king . . . . . . . . . . . . . . . . . . . . . . . 41

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 41

Chec king the W heel Hub Slotted

Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Adjusting the Caster Pi v ot

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Ser vicing the Gear Bo x . . . . . . . . . . . . . . . . . . . . . . 43

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 43

Ser vicing the Cooling System . . . . . . . . . . . . . 43

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 44

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Inspecting the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

R e placing the Mo w er Belt . . . . . . . . . . . . . . . . . . 45

R e placing the PTO Dri v e Belt . . . . . . . . . . . . 45

R e placing the Pump Dri v e

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

R e placing and T ensioning the

Alter nator Belt . . . . . . . . . . . . . . . . . . . 47

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 48

Adjusting the Control Handle

Neutral P osition . . . . . . . . . . . . . . . . 48

Hy draulic System Maintenance . . . . . . . . . . . . . . . . . . 49

Ser vicing the Hy draulic

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Setting the Hy draulic Pump

Neutral P osition . . . . . . . . . . . . . . . . 52

Mo w er Dec k Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 54

Lev eling the Mo w er at T hree

P ositions . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Ser vicing the Cutting Blades . . . . . . . . . . . . . . . 55

R e placing the Grass Deﬂector . . . . . . . . . . . . 58

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Cleaning Under the Mo w er . . . . . . . . . . . . . . . . 58

W aste Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Cleaning and Storag e . . . . . . . . . . . . . . . . . . . . . . . . . 59

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Safety

◊ the type of mac hine is unsuitable for its

task;

T his mac hine meets or ex ceeds European Standards in effect at the time of production. Ho w ev er , improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means CA UTION , W ARNING , or D ANGER-"personal safety instr uction." F ailure to comply with the instr uction ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Training

• R ead the instr uctions carefully . Be familiar with the controls and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use the la wnmo w er . Local regulations can restrict the ag e of the operator .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to other people or their proper ty .

• Do not car r y passeng ers .

• All dri v ers should seek and obtain professional

and practical instr uction. Suc h instr uction should emphasize:

– the need for care and concentration when

w orking with ride-on mac hines;

– control of a ride-on mac hine sliding on a

slope will not be reg ained b y the application of the control lev ers . T he main reasons for loss of control are:

◊ insufﬁcient wheel g rip , especially on

w et g rass;

◊ being dri v en too fast;

◊ inadequate braking;

◊ lac k of a w areness of the effect of

g round conditions , especially slopes;

◊ incor rect hitc hing and load distribution.

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear and long trousers . Do not operate the equipment when barefoot or w earing open sandals .

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning –Fuel is highly ﬂammable .

– Store fuel in containers speciﬁcally designed

for this pur pose .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers .

• Before using, alw a ys visually inspect to see that

the blades , blade bolts and cutter assembly are not w or n or damag ed. R e place w or n or damag ed blades and bolts in sets to preser v e balance .

• On m ulti-bladed mac hines , tak e care as rotating one blade can cause other blades to rotate .

Operation

• Be aler t, slo w do wn and use caution when making tur ns . Look behind and to the side before c hanging directions .

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

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• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes and shift into neutral.

• Do not use on slopes g reater than 15 deg rees .

• R emember there is no suc h thing as a safe

slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– - do not stop or star t suddenly when on

a slope;

– - use slo w speeds on slopes and during

tight tur ns;

– - sta y aler t for humps and hollo ws and

other hidden hazards;

• Use care when pulling loads or using hea vy equipment.

– - Use only appro v ed dra wbar hitc h points . – - Limit loads to those y ou can safely

control.

– - Do not tur n shar ply . Use care when

rev ersing .

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Nev er operate the mac hine with damag ed guards or without safety protecti v e devices in place .

• Do not c hang e the engine g o v er nor settings or o v erspeed the engine . Operating the engine at ex cessi v e speed can increase the hazard of personal injur y .

• Before lea ving the operator’ s position:

– diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine and remo v e the k ey .

• Diseng ag e dri v e to attac hments , stop the engine , and disconnect the spark plug wire(s) or remo v e the ignition k ey

– before clearing bloc kag es or unclog ging

c hute;

– before c hec king, cleaning or w orking on

the la wnmo w er;

– after striking a foreign object. Inspect

the la wnmo w er for damag e and mak e re pairs before restar ting and operating the equipment; if the mac hine star ts to vibrate abnor mally (c hec k immediately).

• Diseng ag e dri v e to attac hments when transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to attac hment

– before refuelling;

– before remo ving the g rass catc her;

– before making height adjustment unless

adjustment can be made from the operator’ s position.

• R educe the throttle setting during engine r un-out and, if the engine is pro vided with a shut-off v alv e , tur n the fuel off at the conclusion of mo wing .

Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes can reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure .

• T o reduce the ﬁre hazard, k ee p the engine , silencer , batter y compar tment and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or deterioration.

• R e place w or n or damag ed par ts for safety .

• If the fuel tank has to be drained, this should

be done outdoors .

• On m ulti-bladed mac hines , tak e care as rotating one blade can cause other blades to rotate .

• W hen mac hine is to be park ed, stored or left unattended, lo w er the cutting means unless a positi v e mec hanical loc k is used.

Toro Riding Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety

Page 6

infor mation that y ou m ust kno w that is not included in the CEN standard.

• Engine exhaust contains carbon mono xide , whic h is an odorless , deadly poison that can kill y ou. Do not r un engine indoors or in an enclosed area.

• K ee p hands , feet, hair and loose clothing a w a y from attac hment disc harg e area, underside of mo w er and any mo ving par ts while engine is r unning .

• Do not touc h equipment or attac hment par ts whic h ma y be hot from operation. Allo w to cool before attempting to maintain, adjust, or ser vice .

• Batter y acid is poisonous and can cause bur ns . A v oid contact with skin, eyes and clothing . Protect y our face , eyes , and clothing when w orking with a batter y .

• Batter y g ases can explode . K ee p cig arettes , sparks and ﬂames a w a y from batter y .

• Use only g en uine T oro re placement par ts to ensure that original standards are maintained.

• Use only T oro-appro v ed attac hments . W ar ranty ma y be v oided if used with unappro v ed attac hments .

• W atc h for ditc hes , holes , roc ks , dips , and rises that c hang e the operating angle , as rough ter rain could o v er tur n the mac hine .

• A v oid sudden star ts when mo wing uphill because the mo w er ma y tip bac kw ards .

• Be a w are that loss of traction ma y occur g oing do wnhill. W eight transfer to the front wheels ma y cause dri v e wheels to slip and cause loss of braking and steering .

• Alw a ys a v oid sudden star ting or stopping on a slope . If tires lose traction, diseng ag e the blades and proceed slo wly off the slope .

• F ollo w the man ufacturer’ s recommendations for wheel w eights or counterw eights to impro v e stability .

• Use extreme care with g rass catc hers or other attac hments . T hese can c hang e the stability of the mac hine and cause loss of control.

Sound Pressure

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 91 dB A, based on measurements of identical mac hines per EN 11094 and EN 836.

Slope Operation

• Do not mo w slopes g reater than 15 deg rees .

• Do not mo w near drop-offs , ditc hes , stee p

banks or w ater . W heels dropping o v er edg es can cause rollo v ers , whic h ma y result in serious injur y , death or dro wning .

• Do not mo w slopes when g rass is w et. Slipper y conditions reduce traction and could cause sliding and loss of control.

• Do not mak e sudden tur ns or rapid speed c hang es .

• Use a w alk behind mo w er and/or a hand trimmer near drop-offs , ditc hes , stee p banks or w ater .

• R educe speed and use extreme caution on slopes .

• R emo v e or mark obstacles suc h as roc ks , tree limbs , etc . from the mo wing area. T all g rass can hide obstacles .

Sound Power

T his unit has a guaranteed sound po w er lev el of 105 dB A, based on measurements of identical mac hines per EN 11094.

Vibration

T his unit does not ex ceed a hand/ar m vibration lev el of 4 m/s identical mac hines per EN 1033. T his unit does not ex ceed a whole body vibration lev el of

1.5 m/s mac hines per EN 1032.

, based on measurements of

, based on measurements of identical

Page 7

Slope Chart

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Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

98-1977

1. Entanglement hazard, belt—stay away from moving parts.

58-6520

1. Grease

98-4387

1. Warning—wear hearing protection.

93-7010

1. Thrown object hazard—

2. Thrown object hazard, mower—keep the deector in place.

3. Cutting/dismemberment of hand or foot—stay away from moving parts.

93-7818

1. Warning—read the Operator’s Manual for instructions on torquing the blade bolt/nut to 115-149 N•m (85-110 ft-lb).

93-8069

1. Hot surface/burn hazard—stay a safe distance from the hot surface.

1. Read the Operator’s Manual .

2. Height of cut

99-8939

3. Remove the ignition key and read the instructions before servicing or performing maintenance.

103-1636

Page 9

104-2449

107-1866

1. Sliding and loss of control hazard and tipping hazard, drop-offs—do not operate the machine near drop-offs, slopes greater than 15 degrees, or water; keep a safe distance from drop-offs; do not turn sharply while traveling fast, instead, slow down and turn gradually; if the roll bar is raised, wear the seat belt; if the roll bar is lowered, do not wear the seat belt.

107-2131

1. Hydraulic oil level 2. Warning—do not touch the hot surface.

107-3069

1. Warning–there is no rollover protection when the roll bar is

down.

2. To avoid injury or death from a rollover accident, keep the

roll bar in the raised and locked position and wear the seat belt. Lower the roll bar only when absolutely necessary; do not wear the the seat belt when the roll bar is down.

3. Read the Operator’s Manual ; drive slowly and carefully.

107-2114

Page 10

1. Height of cut in millimeters

107-3968

1. Disengage

2. Engage

3. Parking brake

107-3969

1. Warning—read the Operator’s Manual .

107-3961

2. Crushing hazard, mower—engage the parking brake, stop the engine, and remove the ignition key before working under the mower.

107-7719

1. Cutting/dismemberment hazard, fan and entanglement hazard, belt—stay away from moving parts.

2. Before starting the engine, clean grass and debris from the mower belt and pulleys, insert the ignition key, and start the engine.

1. Height of cut in millimeters

107-3962

108-5955

Page 11

110-3842

108-5957

108-5981

110-2067

110-2068

1. Read the Operator’s Manual .

110-3851

1. Remove the ignition key and read the instructions before servicing or performing maintenance.

110-3852

1. Remove the ignition key and read the instructions before servicing or performing maintenance.

2. Continuous tone signals the user that engine is overheating.

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1. Cutting/dismemberment hazard, fan and entanglement hazard, belt.

110-3853

2. Remove the ignition key and read the instructions before servicing or performing maintenance.

112-8319

110-0305

Manufacturer’s Mark

1. Indicates the blade is identied as a part from the original machine manufacturer.

1. Push to engage

2. Engine—preheat

3. Read the Operator’s

4. Engine—stop

5. Engine—run

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

112-2389

6. Engine—start

7. Fast

8. Continuous variable setting

Manual.

9. Slow

10. PTO (Power take off)

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

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

8. Battery acid can cause blindness or severe burns.

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

10. Contains lead; do not discard.

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1. Cutting/dismemberment hazard, mower blade—do not carry passengers and keep bystanders away.

2. Cutting/dismemberment hazard of hand or foot, mower blade—remove the ignition key and read the instructions before servicing or performing maintenance; stay away from moving parts.

107-3963

3. Thrown object hazard—keep bystanders a safe distance from the machine and keep the deector in place.

4. Before starting the engine, clean grass and debris from the mower belt and pulleys, insert the ignition key, and start the engine.

107-3964

1. Warning—do not use drugs or alcohol. 3. Warning—engage the parking brake,

2. Warning—read the Operator’s Manual and receive training.

stop the engine, and remove the ignition key before leaving the machine.

4. Warning—wear hearing protection.

5. Read the Operator’s Manual .

Page 14

110-0820

1. Fast

2. Slow 6. Poison and caustic liquid/chemical burn hazard—keep children

3. Neutral 7. Explosion hazard—no re, open ames, or smoking; avoid

4. Reverse

5. Warning—read the Operator’s Manual .

a safe distance from the battery.

sparks.

8. To unlock the traction drive, turn the by-pass valve 1 complete revolution counterclockwise using a 5/8 inch or 16 mm wrench.

Page 15

Product Overview

Hour Meter

T he hour meter records the n umber of hours the engine has operated. It operates when the engine is r unning . Use these times for sc heduling regular maintenance ( Figure 4 ).

Glow Plug Light

T he glo w plug indicator light tur ns on when the glo w plug button is eng ag ed ( Figure 4 ).

Glow Plug Switch

T his switc h acti v ates the glo w plugs and is indicated b y the glo w plug light. Hold do wn the glo w plug switc h for 10 seconds prior to star ting .

Temperature Light

Figure 3

1. Motion control lever 6. Controls

2. Parking brake lever 7. Seat belt

3. Height-of-cut lever 8. Roll bar

4. Fuel cap (both sides)

5. Lift-assist lever

9. Engine screen

Controls

Become familiar with all the controls before y ou star t the engine and operate the mac hine ( Figure 3 and Figure 4 ).

T he temperature light comes on when the engine is o v er heating ( Figure 4 ).

Audible Alarm

T his mac hine has an audible alar m that aler ts the user to tur n off the engine or engine damag e can occur from o v er heating . R efer to Ser vicing the Cooling System in Cooling System Maintenance , pag e 43 .

Fuel Selector Valve

T he fuel selector v alv e is located behind the seat.

Close the fuel selector v alv e when transpor ting or storing mo w er .

Mo v e the selector v alv e to the lefthand (LH) or righthand (RH) position for operation.

Figure 4

1. Hour meter

2. Ignition switch 7. PTO Switch

3. Glow plug switch 8. Audible alarm

4. Glow plug light 9. Fuel selector valve

5. Engine Temperature light

6. Throttle control

Page 16

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Adding Fuel

T he engine r uns on clean, fresh diesel fuel with a minim um octane rating of 40. Purc hase fuel in quantities that can be used within 30 da ys to ensure fuel freshness .

Use summer g rade diesel fuel (No . 2-D) at temperatures abo v e 20° F (-7° C) and winter g rade diesel fuel (No . 1-D or No . 1-D/2-D blend) belo w 20° F (-7° C). Use of winter g rade diesel fuel at lo w er temperatures pro vides lo w er ﬂash point and pour point c haracteristics , therefore easing star tability and lessening c hances of c hemical se paration of the fuel due to lo w er temperatures (w ax appearance , whic h ma y plug ﬁlters).

Use of summer g rade diesel fuel abo v e 20° F (-7° C) will contribute to w ard long er life of the pump components .

Important: Do not use k er osene or gasoline instead of diesel fuel. F ailur e to obser v e this caution will dama ge the engine.

In cer tain conditions, fuel is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om fuel can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y fuel that spills.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

• Do not ﬁll the fuel tank completel y full. Add fuel to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws fuel to expand.

• Nev er smok e when handling fuel, and stay a w ay fr om an open ﬂame or wher e fuel fumes may be ignited by a spar k.

• Stor e fuel in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of fuel.

• Al w ays place fuel container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

Fuel is har mful or f atal if s w allo w ed. Long-ter m exposur e to v apor s can cause serious injur y and illness.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

• Do not ﬁll fuel container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a fuel dispenser nozzle.

• If a fuel dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

Filling the Fuel Tank

1. Shut the engine off and set the parking brak e .

Page 17

2. Clean around eac h fuel tank cap and remo v e the cap . Add fuel to both fuel tanks , until the lev el is 1/4 to 1/2 inc h (6 to 13 mm) belo w the bottom of the ﬁller nec k. T his space in the tank allo ws the fuel to expand. Do not ﬁll the fuel tanks completely full.

3. Install fuel tank caps securely . Wipe up any fuel that ma y ha v e spilled.

4. If possible , ﬁll the fuel tank after eac h use . T his will minimize possible buildup of condensation inside the fuel tank.

Checking the Engine Oil Level

Before y ou star t the engine and use the mac hine , c hec k the oil lev el in the engine crankcase; refer to Chec king Oil Lev el in Engine Maintenance , pag e 33

Switching the Fuel Tanks

Figure 5

1. Left side fuel tank 2. Fuel selector valve

Important: Do not r un the machine out of fuel. T his may cause engine dama ge and r equir e the fuel system to be check ed.

T he fuel selector v alv e is located behind the left side of the seat.

T he unit has tw o fuel tanks . One tank is on the left side and one on the right side . Eac h tank connects to the fuel selector v alv e . F rom there a common fuel line leads to the engine ( Figure 5 ).

T o use the left side fuel tank rotate the fuel selector v alv e to the LH, lefthand location. T o use the right side fuel tank rotate the fuel selector v alv e to the RH, righthand location ( Figure 5 )

Close the fuel selector v alv e before transpor ting or storing mac hine .

Using the Rollover Protection System (ROPS)

T o a v oid injur y or death fr om r ollo v er : k eep the r oll bar in the raised lock ed position and use the seat belt.

Ensur e that the r ear par t of the seat is secur ed with the seat latch.

Page 18

T her e is no r ollo v er pr otection when the r oll bar is in the do wn position.

• Lo w er the r oll bar onl y when a bsolutel y necessar y .

• Do not w ear the seat belt when the r oll bar is in the do wn position.

• Dri v e slo wl y and car efull y .

• R aise the r oll bar as soon as clearance per mits.

• Check car efull y f or o v erhead clearances (i.e. branches, doorw ays, electrical wir es) bef or e dri ving under an y objects and do not contact them.

Important: Lo w er the r oll bar onl y when a bsolutel y necessar y .

1. R emo v e the hair pin cotter pins and remo v e the tw o pins ( Figure 7 ).

4. T o raise the roll bar , remo v e the hair pin cotter pins and remo v e the tw o pins ( Figure 7 ).

5. Raise the roll bar to the upright position and install the tw o pins and secure them with the hair pin cotter pins ( Figure 7 ).

Important: Al w ays use the seat belt with the r oll bar in the raised position.

2. Lo w er the roll bar to the do wn position. T here are tw o do wn positions . See Figure 6 for the positions .

3. Install the tw o pins and secure them with the hair pin cotter pins ( Figure 7 ).

Figure 6

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

Figure 7

1. Roll bar

2. Raised position

3. Pin

4. Hairpin cotter pin

Think Safety First

Please read all safety instr uctions and symbols in the safety section. Kno wing this infor mation could help y ou or b ystanders a v oid injur y .

Important: Ensur e that the r ear par t of the seat is secur ed with the seat latch.

Page 19

Operating on w et g rass or steep slopes can cause sliding and loss of contr ol.

W heels dr opping o v er edges can cause r ollo v er s, which may r esult in serious injur y , death or dr o wning .

T her e is no r ollo v er pr otection when the r oll bar is do wn.

Al w ays k eep the r oll bar in the raised and lock ed position and use the seat belt.

R ead and f ollo w the r ollo v er pr otection instr uctions and w ar nings.

T o a v oid loss of contr ol and possibility of r ollo v er :

T his machine pr oduces sound lev els in ex cess of 85 dB A at the operator s ear and can cause hearing loss thr ough extended periods of exposur e.

W ear hearing pr otection when operating this machine.

W ear protecti v e equipment for y our eyes , ears , feet, and head when using this mac hine .

• Do not operate near dr op-of fs or near w ater .

• Do not operate on slopes g r eater than 15 deg r ees.

• R educe speed and use extr eme caution on slopes.

• A v oid sudden tur ns or rapid speed changes.

Figure 9

1. Warning— wear hearing protection

Operating the Parking Brake

Alw a ys set the parking brak e when y ou stop the mac hine or lea v e it unattended.

Setting the Parking Brake

1. Mo v e the motion control lev ers ( Figure 15 ) out to the neutral loc k position.

2. Pull up and bac k on the parking brak e lev er to set the parking brak e ( Figure 10 ). T he parking brak e lev er should sta y ﬁr mly in the eng ag ed position.

P ar king brak e may not hold machine par k ed on a slope and could cause per sonal injur y or pr oper ty dama ge.

1. Safe Zone-use the Z Master here on slopes less than 15 degrees or at areas.

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

Figure 8

Do not par k on slopes unless wheels ar e

3. Water

chock ed or block ed

Releasing the Parking Brake

Push forw ard and do wn on the parking brak e lev er to release the parking brak e ( Figure 10 ). T he parking brak e is diseng ag ed and the lev er will rest ag ainst the brak e stop .

Page 20

Figure 10

1. Parking brake-ON 3. Brake Stop

2. Parking brake-OFF

Figure 11

1. Hour meter

2. Ignition switch 7. PTO Switch

3. Glow plug switch 8. Audible alarm

4. Glow plug light 9. Fuel selector valve

5. Engine Temperature light

6. Throttle control

Starting and Stopping the Engine

Starting the Engine in Normal Weather

1. Raise the R OPS up and loc k into place , sit on the seat and fasten the seat belt.

2. Mo v e the motion controls to the neutral loc k ed position.

3. Set the parking brak e; refer to Setting the P arking Brak e .

4. Mo v e the PTO (po w er tak e off) switc h to the off position ( Figure 11 ).

5. Mo v e the throttle lev er to the middle position ( Figure 13 ).

6. T ur n the ignition k ey cloc kwise to the r un position ( Figure 12 ).

7. Push the glo w plug switc h for 10 seconds . T he light will tur n on.

9. T ur n the k ey to the star t position and the glo w plug indicator light will come bac k on. W hen the engine star ts , release the k ey ( Figure 12 ).

Important: Use star ting cy cles of no mor e than 30 seconds per min ute to a v oid o v erheating the star ter motor .

10. If the engine does not star t immediately , mo v e the throttle control to fast and tur n the k ey to the star t position.

Note: Additional star ting cycles ma y be required when star ting the engine for the ﬁrst time after the fuel system has been completely without fuel.

8. R elease the switc h after 10 seconds . T he light will tur n off .

Figure 12

1. Ignition switch

2. Off

3. Run

4. Start

Page 21

Figure 13

1. Throttle—fast 2. Throttle—slow

Starting the Engine in Cold Weather (Below 23°F or -5°C)

3. Let the engine idle for 60 seconds .

4. T ur n the ignition k ey to the off position ( Figure 12 ). W ait for all mo ving par ts to stop before lea ving the operating position.

5. R emo v e the k ey to prev ent possibility of someone accidentally star ting the mac hine before transpor ting or storing mac hine .

6. Close the fuel selector v alv e before transpor ting or storing the mac hine .

Important: Mak e sur e that the fuel selector v alv e is closed bef or e transpor ting or storing the machine, as fuel leaka ge may occur . Set the par king brak e bef or e transpor ting .

Important: Mak e sur e to r emo v e the k ey as the fuel pump may r un and cause the batter y to lose charge.

Note: Use the cor rect engine oil for the star ting temperature . R efer to Ser vicing the Engine Oil in Engine Maintenance , pag e 33 .

1. Star t the engine with the throttle in the F ast position.

2. T ur n the ignition k ey cloc kwise to the r un position ( Figure 12 ).

3. Push the glo w plug switc h for 10 to 15 seconds . T he light will tur n on.

4. R elease the switc h after 10 to 15 seconds . T he light will tur n off .

5. T ur n the k ey to the star t position and the glo w plug indicator light will come bac k on. W hen the engine star ts , release the k ey .

Important: Use star ting cy cles of no mor e than 30 seconds per min ute to a v oid o v erheating the star ter motor .

Note: Do not use fuel left o v er from the summer . Use only fresh winter g rade diesel fuel.

Stopping the Engine

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e ( Figure 14 ).

2. Mo v e the throttle lev er midw a y betw een the slo w and fast positions ( Figure 13 ).

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the tractor while it is unattended.

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

Operating the Power Take Off (PTO)

T he po w er tak e off (PTO) switc h star ts and stops the mo w er blades and any po w ered attac hments .

Engaging the PTO

1. If the engine is cold, allo w the engine to w ar m up 5 to 10 min utes before eng aging the PTO .

2. W hile seated in the seat, release the pressure on the traction control lev ers and place in neutral.

3. Place the throttle in the fast position. Note: Eng aging the PTO with the throttle

at the half or less position will cause ex cessi v e w ear to the dri v e belts .

4. Pull out on the po w er tak e off (PTO) switc h to eng ag e it ( Figure 14 ).

Page 22

1. PTO-On

Disengaging the PTO

Figure 14

eng ag ed or if y ou rise from the seat when the PTO is eng ag ed.

Testing the Safety Interlock System

T est the safety interloc k system before y ou use the mac hine eac h time . If the safety system does not operate as described belo w , ha v e an A uthorized Ser vice Dealer re pair the safety system immediately .

1. Sitting on the seat, eng ag e the parking brak e and mo v e the PTO to on. T r y star ting the engine; the engine should not crank.

2. PTO-Off

2. Sitting on the seat, eng ag e the parking brak e and mo v e the PTO to off . Mo v e either motion control lev er (out of neutral loc k ed position). T r y star ting the engine; the engine should not crank. R e peat for other control lev er .

T o diseng ag e , push the PTO switc h to the of f position ( Figure 14 ).

The Safety Interlock System

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

Understanding the Safety Interlock System

T he safety interloc k system is designed to prev ent the engine from star ting unless:

3. Sitting on the seat, eng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. No w star t the engine . W hile the engine is r unning, release the parking brak e , eng ag e the PTO and rise slightly from the seat; the engine should stop .

4. Sitting on the seat, eng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. No w star t the engine . W hile the engine is r unning, center either motion control and mo v e (forw ard or rev erse); the engine should stop . R e peat for other motion control.

5. Sitting on the seat, diseng ag e the parking brak e , mo v e the PTO switc h to off and mo v e the motion control lev ers to neutral loc k position. T r y star ting the engine; the engine should not crank.

Driving Forward or

• Y ou are sitting on the seat.

• T he parking brak e is eng ag ed.

• T he po w er tak e off (PTO) is diseng ag ed.

• T he motion control lev ers are in the neutral

loc k ed position

T he safety interloc k system also is designed to stop the engine when the traction controls are mo v ed from the loc k ed position with the parking brak e

Backward

T he throttle control regulates the engine speed as measured in r pm (rev olutions per min ute). Place the throttle control in the fast position for best perfor mance . Alw a ys operate in the full throttle position when mo wing .

Page 23

Machine can spin v er y rapidl y . Operator may lose contr ol of machine and cause per sonal injur y or dama ge to machine.

• Use caution when making tur ns.

• Slo w the machine do wn bef or e making shar p tur ns.

Driving Forward

1. R elease the parking brak e; refer to R eleasing the P arking Brak e in Operation , pag e 16 .

2. Mo v e the lev ers to the center , un-loc k ed position.

Driving Backward

1. Mo v e the lev ers to the center , un-loc k ed position.

2. T o g o bac kw ard, slo wly pull the motion control lev ers rearw ard ( Figure 15 ).

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 15 ).

T o tur n, release pressure on the motion control lev er to w ard the direction y ou w ant to tur n ( Figure 15 ).

T o stop , push the motion control lev ers to the neutral position.

Stopping the Machine

3. T o g o forw ard, slo wly push the motion control lev ers forw ard ( Figure 15 ).

Note: T he engine will kill if the traction control lev ers are mo v ed with the parking brak e eng ag ed.

T o g o straight, apply equal pressure to both motion control lev ers ( Figure 15 ).

T o tur n, mo v e the motion control lev er to w ard neutral in the direction y ou w ant to tur n ( Figure 15 ).

T he far ther y ou mo v e the traction control lev ers in either direction, the faster the mac hine will mo v e in that direction.

T o stop , pull the motion control lev ers to the neutral position.

T o stop the mac hine , mo v e the traction control lev ers to neutral and mo v e to loc k ed position, diseng ag e the po w er tak e off (PTO), and tur n the ignition k ey to off .

Set the parking brak e when y ou lea v e the mac hine; refer to Setting the P arking Brak e in Operation , pag e 16 . R emember to remo v e the k ey from the ignition switc h.

Childr en or bystander s may be injur ed if they mo v e or attempt to operate the tractor while it is unattended.

Al w ays r emo v e the ignition k ey and set the par king brak e when lea ving the machine unattended, ev en if just f or a few min utes.

Adjusting the Height-of-Cut

T he height-of-cut is adjusted from 1-1/2 to 5 inc h (38 to 127 mm) in 1/4 inc h (6 mm) increments b y relocating the clevis pin into different hole locations .

Figure 15

1. Motion control lever-neutral lock position

2. Center un-lock position 4. Backward

1. Raise the height-of-cut lev er to the transpor t position (also the 5 inc h (127 mm) cutting height position) ( Figure 16 ).

2. T o adjust, remo v e the clevis pin from the height-of-cut brac k et ( Figure 16 ).

3. Select a hole in the height-of-cut brac k et

3. Forward

cor responding to the height-of-cut desired and, inser t the clevis pin ( Figure 16 ).

4. Mo v e the lev er to the selected height.

Page 24

Figure 16

1. Height of cut lever 2. Clevis Pin

Adjusting the Anti-Scalp Rollers

W henev er y ou c hang e the height-of-cut, it is recommended to adjust the height of the anti-scalp rollers .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

Figure 17

1. Anti-scalp roller 4. Flange Nut

2. Spacer

3. Bushing

5. Bolt

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. After adjusting the height-of-cut, adjust the rollers b y remo ving the ﬂang e n ut, bushing, spacer , and bolt ( Figure 17 , Figure 18 and Figure 19 ).

Note: T he tw o middle rollers will not ha v e a spacer ( Figure 18 ).

4. Select a hole so the anti-scalp roller is positioned to the nearest cor responding height-of-cut desired.

5. Install the ﬂang e n ut bushing, spacer , and bolt. T or que to 40-45 ft-lb (54-61 N•m) ( Figure 17 , Figure 18 and Figure 19 ).

6. R e peat this adjustment on the other anti-scalp rollers .

Figure 18

1. Anti-scalp roller 3. Flange Nut

2. Bushing 4. Bolt

Figure 19

1. Anti-scalp roller 4. Flange Nut

2. Spacer

3. Bushing

5. Bolt

Page 25

Adjusting the Flow Bafe

T he mo w er disc harg e ﬂo w can be adjusted for different types of mo wing conditions . P osition the cam loc ks and bafﬂe to gi v e the best quality of cut.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. T o adjust the cam loc ks , swing the lev er up to loosen the cam loc k ( Figure 20 ).

4. Adjust the bafﬂe and cam loc ks in the slots to the desired disc harg e ﬂo w .

5. Swing the lev er bac k o v er to tighten the bafﬂe and cam loc ks ( Figure 20 ).

6. If the cams do not loc k the bafﬂe into place or it is too tight, loosen the lev er and then rotate the cam loc k. Adjust the cam loc k until the desired loc king pressure is ac hiev ed.

• Use in dr y conditions .

• F or smaller g rass clippings .

• Propels g rass clippings far ther a w a y from the

mo w er .

Figure 21

Position B

Use this position when bag ging .

Figure 20

1. Cam lock

2. Lever

3. Rotate cam to increase or decrease locking pressure

4. Slot

Positioning the Flow Bafe

T he follo wing ﬁgures are only recommendations for use . Adjustments will v ar y b y g rass type , moisture content, and height of g rass .

Note: If the engine po w er dra ws do wn and the mo w er g round speed is the same , open up the bafﬂe .

Position A

T his is the full rear position. T he sug g ested use for this position is a follo ws .

• Use for shor t, light g rass mo wing conditions .

Figure 22

Position C

T his is the full open position. T he sug g ested use for this position is as follo ws .

• Use in tall, dense g rass mo wing conditions .

• Use in w et conditions .

• Lo w ers the engine po w er consumption.

• Allo ws increased g round speed in hea vy

conditions .

• T his position is similar to the beneﬁts of the T oro SFS mo w er .

Page 26

Positioning the Seat

Figure 24

1. Seat suspension knob 2. Seat position lever

Figure 23

Changing the Back Position

T he bac k of the seat can be adjusted to pro vide a comfor table ride . P osition the bac k of the seat where it is most comfor table .

Changing the Seat Position

T he seat can mo v e forw ard and bac kw ard. P osition the seat where y ou ha v e the best control of the mac hine and are most comfor table .

1. T o adjust, mo v e the lev er sidew a ys to unloc k seat ( Figure 24 ).

2. Slide the seat to the desired position and release the lev er to loc k it in position.

Changing the Seat Suspension

T he seat can be adjusted to pro vide a smooth and comfor table ride . P osition the seat where y ou are most comfor table .

T o adjust, tur n the knob in front either direction to pro vide the best comfor t ( Figure 24 ).

T o adjust, tur n the knob , under the rightside ar m rest, in either direction to pro vide the best comfor t ( Figure 25 ).

Figure 25

1. Back rest knob 2. Rightside arm rest

Unlatching the Seat

Push the seat latc h rearw ard to unlatc h the seat. T his will allo w access to the mac hine under the seat ( Figure 26 ).

Page 27

Figure 26

1. Seat latch

2. Fuel cap

3. Seat

Pushing the Machine by Hand

Important: Al w ays push the machine

by hand. Nev er to w the machine because h y draulic dama ge may occur .

Pushing the Machine

1. Diseng ag e the po w er tak e off (PTO) and tur n the ignition k ey to off . Mo v e the lev ers to neutral loc k ed position and apply parking brak e . R emo v e the k ey .

2. R otate the b y-pass v alv es countercloc kwise 1 tur n to push. T his allo ws h y draulic ﬂuid to b y-pass the pump enabling the wheels to tur n ( Figure 27 ).

Important: Do not r otate by-pass v alv es mor e than 1 tur n. T his pr ev ents v alv es fr om coming out of the body and causing ﬂuid to r un out.

3. Diseng ag e parking brak e before pushing .

Changing to Machine Operation

Figure 27

1. Side console controls 3. Hydraulic pumps

2. By-pass valve

Using the Side Discharge

T he mo w er has a hing ed g rass deﬂector that disperses clippings to the side and do wn to w ard the turf .

W ithout the g rass deﬂector , discharge co v er , or complete g rass catcher assembl y mounted in place, y ou and other s ar e exposed to blade contact and thr o wn de bris. Contact with r otating mo w er blade(s) and thr o wn de bris will cause injur y or death.

• Nev er r emo v e the g rass deﬂector fr om the mo w er because the g rass deﬂector r outes material do wn to w ard the turf. If the g rass deﬂector is ev er dama ged, r eplace it immediatel y .

• Nev er put y our hands or feet under the mo w er .

R otate the b y-pass v alv es cloc kwise 1 tur n to operate mac hine ( Figure 27 ).

Note: Do not o v er tighten the b y-pass v alv es .

T he mac hine will not dri v e unless b y-pass v alv es are tur ned in.

• Nev er tr y to clear the discharge ar ea or mo w er blades unless y ou mo v e the po w er tak e of f (PT O) to the of f position, r otate the ignition k ey to of f and r emo v e the k ey .

• Mak e sur e the g rass deﬂector is in the do wn position.

Page 28

Transporting Machines

Use a hea vy-duty trailer or tr uc k to transpor t the mac hine . Ensure that the trailer or tr uc k has all necessar y lighting and marking as required b y la w . Please carefully read all the safety instr uctions . Kno wing this infor mation could help y ou, y our family , pets or b ystanders a v oid injur y .

T o transpor t the mac hine:

Important: Do Not attempt to tur n the unit while on the ramp; y ou may lose contr ol and dri v e of f the side.

A v oid sudden acceleration when dri ving up a ramp and sudden deceleration when bac king do wn a ramp . Both maneuv ers can cause the unit to tip bac kw ard.

• Loc k the brak e and bloc k the wheels .

• Securely fasten the mac hine to the trailer or

tr uc k with straps , c hains , cable , or ropes .

• Secure a trailer to the to wing v ehicle with safety c hains .

Dri ving on the str eet or r oad w ay without tur n signals, lights, r eﬂecti v e mar kings, or a slo w mo ving v ehicle emblem is danger ous and can lead to accidents causing per sonal injur y .

Do not dri v e machine on a public str eet or r oad w ay .

Loading Machines

Use extreme caution when loading units on trailers or tr uc ks . One full width ramp that is wide enough to extend bey ond the rear tires is recommended instead of indi vidual ramps for eac h side of the unit ( Figure 28 ). T he lo w er rear section of the tractor frame extends bac k betw een the rear wheels and ser v es as a stop for tipping bac kw ard. Ha ving a full width ramp pro vides a surface for the frame members to contact if the unit star ts to tip bac kw ard. If it is not possible to use one full width ramp , use enough indi vidual ramps to sim ulate a full width contin uous ramp .

Loading a unit onto a trailer or tr uck incr eases the possibility of backw ard tip-o v er and could cause serious injur y or death.

• Use extr eme caution when operating a unit on a ramp .

• Use onl y a sing le, full width ramp; Do Not use indi vidual ramps f or each side of the unit.

• If indi vidual ramps must be used, use enough ramps to cr eate an unbr ok en ramp surf ace wider than the unit.

• Do not ex ceed a 15 deg r ee ang le betw een ramp and g r ound or betw een ramp and trailer or tr uck.

• A v oid sudden acceleration while dri ving unit up a ramp to a v oid tipping backw ard.

• A v oid sudden deceleration while backing unit do wn a ramp to a v oid tipping backw ard.

T he ramp should be long enough so that the angles do not ex ceed 15 deg rees ( Figure 28 ). A stee per angle ma y cause mo w er components to g et caught as the unit mo v es from ramp to trailer or tr uc k. Stee per angles ma y also cause the unit to tip bac kw ard. If loading on or near a slope , position the trailer or tr uc k so it is on the do wn side of the slope and the ramp extends up the slope . T his will minimize the ramp angle . T he trailer or tr uc k should be as lev el as possible .

Page 29

Mowing Direction

Alter nate mo wing direction to k ee p the g rass standing straight. T his also helps disperse clippings whic h enhances decomposition and fer tilization.

Mow at Correct Intervals

Nor mally , mo w ev er y four da ys . But remember , g rass g ro ws at different rates at different times . So to maintain the same cutting height, whic h is a g ood practice , mo w more often in early spring . As the g rass g ro wth rate slo ws in mid summer , mo w less frequently . If y ou cannot mo w for an extended period, ﬁrst mo w at a high cutting height; then mo w ag ain tw o da ys later at a lo w er height setting .

Cutting Speed

Figure 28

1. Trailer 3. Not greater than 15 degrees

2. Full width ramp 4. Full width ramp—side view

Operating Tips

Fast Throttle Setting

F or best mo wing and maxim um air circulation, operate the engine at the fast throttle position. Air is required to thoroughly cut g rass clippings , so do not set the height-of-cut so lo w as to totally sur round the mo w er b y uncut g rass . Alw a ys tr y to ha v e one side of the mo w er free from uncut g rass , whic h allo ws air to be dra wn into the mo w er .

Cutting a Lawn for the First Time

Cut g rass slightly long er than nor mal to ensure the cutting height of the mo w er does not scalp any unev en g round. Ho w ev er , the cutting height used in the past is g enerally the best one to use . W hen cutting g rass long er than six inc hes tall, y ou ma y w ant to cut the la wn twice to ensure an acce ptable quality of cut.

Cut 1/3 of the Grass Blade

T o impro v e cut quality , use a slo w er g round speed in cer tain conditions .

Avoid Cutting Too Low

If the cutting width of the mo w er is wider than the mo w er y ou previously used, raise the cutting height to ensure that unev en turf is not cut too shor t.

Long Grass

If the g rass is ev er allo w ed to g ro w slightly long er than nor mal, or if it contains a high deg ree of moisture , raise the cutting height higher than usual and cut the g rass at this setting . T hen cut the g rass ag ain using the lo w er , nor mal setting .

When Stopping

If the mac hine’ s forw ard motion m ust be stopped while mo wing, a clump of g rass clippings ma y drop onto y our la wn. T o a v oid this , mo v e onto a previously cut area with the blades eng ag ed.

Keep the Underside of the Mower Clean

Clean clippings and dir t from the underside of the mo w er after eac h use . If g rass and dir t build up inside the mo w er , cutting quality will ev entually become unsatisfactor y .

It is best to cut only about 1/3 of the g rass blade . Cutting more than that is not recommended unless g rass is sparse , or it is late fall when g rass g ro ws more slo wly .

Blade Maintenance

Maintain a shar p blade throughout the cutting season because a shar p blade cuts cleanly without tearing or shredding the g rass blades . T earing and

Page 30

shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease . Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a g en uine TOR O re placement blade .

Page 31

Maintenance

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 25

operating hours

After the rst 50

operating hours

After the rst 100

operating hours

Before each use or daily

Every 25 hours

Every 50 hours

Maintenance Procedure

• Check the hydraulic uid level.

• Change the hydraulic lter and oil.

• Change the engine oil.

• Change the engine oil lter.

• Change gear box oil.

• Check the engine oil.

• Check the engine coolant level.

• Clean the engine oil cooler.

• Check the mower blades.

• Clean the mower deck.

• Grease the mower deck and spindles.

• Grease the mower belt idler arm.

• Grease the pump belt idler arm.

• Grease the drive belt idler arm.

• Grease the brake lever.

• Check the hydraulic uid level.

• Check the tire pressure.

• Check the PTO drive belt.

• Check the pump drive belt.

• Check the alternator belt.

• Change the engine oil.

• Check the gear box oil level.

Every 100 hours

Every 150 hours

Every 200 hours

Every 250 hours

Every 400 hours

Every 500 hours

Yearly

• Check the cooling system hoses.

• Inspect the belts for cracks and wear.

• Check the hydraulic hoses.

• Lubricate the machine with light oil (Refer to Lubrication).

• Change the engine oil lter.

• Grease the brake pivot.

• Check and/or replace the air lter (more often in dirty or dusty conditions).

• Replace the fuel lters.

• Check the wheel hub slotted nut.

• Adjust the caster pivot bearing.

• Grease the front caster pivots (more often in dirty or dusty conditions).

• Change the gear box oil.

• Change the engine coolant.

• Change the hydraulic lter and oil.

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

Page 32

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the wir e fr om the spar k plug(s) bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

Lubrication

Greasing and Lubrication

Lubricate the mac hine when sho wn on the Chec k Ser vice R eference Aid decal ( Figure 29 ). Grease more frequently when operating conditions are extremely dusty or sandy .

Grease T ype: General-pur pose g rease .

How to Grease

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean the g rease ﬁttings with a rag . Mak e sure to scrape any paint off the front of the ﬁtting(s).

Where to Add Grease

Lubricate the g rease ﬁttings as sho wn on the Chec k Ser vice R eference Aid decal ( Figure 29 ).

4. Connect a g rease gun to the ﬁtting . Pump g rease into the ﬁttings until g rease begins to ooze out of the bearings .

5. Wipe up any ex cess g rease .

Greasing the Front Caster Pivots

Lubricate the front caster pi v ots once a year .

1. R emo v e the dust cap and adjust the caster pi v ots . K ee p the dust cap off until g reasing is done . R efer to Adjusting the Caster Pi v ot Bearing in Dri v e System Maintenance , pag e 41 .

2. R emo v e the hex plug . T hread a g rease zerk into the hole .

3. Pump g rease into the zerk until it oozes out around the top bearing .

4. R emo v e the g rease zerk in the hole . Install the hex plug and cap .

Figure 29

Where to Add Light Oil or Spray Lubrication

Lubricate the mac hine in the follo wing areas with spra y type lubricant or light oil. Lubricate ev er y 150 hours .

• Seat switc h actuator .

• Brak e handle pi v ot.

• Brak e rod bushings .

• Motion control bronze bushings .

Page 33

Greasing the Mower Deck and Belt Idlers

T he mo w er dec k m ust be lubricated w eekly or ev er y 25 hours . Grease with No . 2 g eneral pur pose lithium base or molybden um base g rease .

Important: Mak e sur e cutting unit spindles ar e full of g r ease w eekl y .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the belt co v ers .

7. Grease the PTO dri v e belt idler ar m ( Figure 31 ).

8. Grease the pump belt idler ar m ( Figure 31 ).

4. Grease the three spindle bearings under the pulleys until g rease comes out the lo w er seals ( Figure 30 ).

5. Grease the idler ar m on the mo w er dec k ( Figure 30 ).

6. Grease the ﬁttings on the push ar ms ( Figure 30 ).

Figure 30

Figure 31

Engine Maintenance

Servicing the Air Cleaner

Air Filter : Chec k and/or re place after ev er y 250 operating hours or more often in dusty conditions .

Note: Chec k the ﬁlters more frequently if operating conditions are extremely dusty or sandy .

Removing the Air Filter

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R elease the latc hes on the air cleaner and pull the air cleaner co v er off of the air cleaner body ( Figure 32 ).

4. Clean the inside of the air cleaner co v er with compressed air .

5. Gently slide the ﬁlter out of the air cleaner body ( Figure 32 ). A v oid knoc king the ﬁlter into the side of the body .

6. Inspect the ﬁlter for damag e b y looking into the ﬁlter while shining a bright light on the outside of the ﬁlter . Holes in the ﬁlter will

Page 34

appear as bright spots . If the ﬁlter is damag ed discard it.

Figure 32

1. Air lter body 3. Air cleaner cover

2. Air lter 4. Latches

Installing the Air Filter

1. If installing a new ﬁlter , c hec k the ﬁlter for shipping damag e . Do not use a damag ed ﬁlter .

2. Carefully slide the ﬁlter into the ﬁlter body ( Figure 33 ). Ensure that it is fully seated b y pushing on the outer rim of the ﬁlter while installing it.

Important: Do not pr ess on the soft inside ar ea of the ﬁlter .

3. Install the air cleaner co v er and secure the latc hes ( Figure 33 ).

Figure 33

1. Air lter body 3. Air cleaner cover

2. Air lter 4. Latches

Servicing the Engine Oil

Chang e the engine oil as follo ws:

• After the ﬁrst 50 operating hours .

• Ev er y 100 hours after the ﬁrst 25 operating

hours .

Oil T ype: High-quality deterg ent oil classiﬁed API Ser vice CD or higher for diesel engines . Do not use special additi v es with recommended oils .

Crankcase Capacity: 3.9 quar ts (3.7 liters)

Viscosity: See the table belo w:

Page 35

Figure 34

Checking the Engine Oil Level Note: Chec k the oil when the engine is cold.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Clean around the oil dipstic k ( Figure 35 ) so dir t cannot fall into the ﬁller hole and damag e the engine .

4. Pull the oil dipstic k out and wipe the metal end clean ( Figure 35 ).

5. Slide the oil dipstic k fully into the ﬁller tube . Pull the dipstic k out and look at the metal end ( Figure 35 ). If the oil lev el is lo w , slo wly pour only enough oil into the ﬁll hole to raise the lev el to the full mark.

Figure 35

1. Oil dipstick 3. Rear left side of machine

2. Metal end

Changing the Engine Oil

1. Star t the engine and let it r un for ﬁv e min utes . T his w ar ms the oil so it drains better .

2. P ark the mac hine on a lev el surface .

3. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

4. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Important: Do not o v erﬁll the crankcase with oil because this may cause engine dama ge. Do not r un the engine with oil belo w the lo w mar k because the engine may be dama ged as a r esult.

5. Place a pan belo w the oil drain. R emo v e the drain plug and let the oil drain completely ( Figure 36 ).

6. R emo v e the oil ﬁller cap from the top of the engine ( Figure 38 ). T his will help the oil to drain.

7. Install the drain plug and tighten it to 25-1/2 ft-lb (35 N•m).

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

Page 36

Figure 38

1. Engine

2. Oil ll cap

Figure 36

1. Back of machine 2. Drain plug

Adding Engine Oil

1. Tilt the seat forw ard, loosen the bolts and remo v e the front engine panel ( Figure 37 ).

3. T o add oil to the engine , locate and use a hose and funnel for adding oil ( Figure 39 ).

4. Add oil slo wly , c hec king the lev el with the dipstic k frequently until the lev el reac hes the upper hole on the dipstic k. F or the cor rect oil type and viscosity to use in different temperature conditions , refer to Ser vicing the Engine Oil in Engine Maintenance , pag e 33 , ).

Figure 37

1. Bolt 2. Front engine panel

2. R emo v e the oil ﬁller cap and the dipstic k ( Figure 38 ).

Figure 39

1. Engine oil 2. Funnel and hose

Page 37

Important: Add the oil v er y slo wl y and do not block the opening of the ﬁller hole ( Figur e 40 ). If y ou add oil too f ast or block the hole, the oil could back up and f oul the air intak es, causing engine dama ge.

Figure 40

1. Note the clearance left in the ller opening.

5. R e place the dipstic k and install the front engine panel.

6. Star t the engine and r un it at idle for 5 min utes .

3. Before installing the ﬁlter , lightly oil the g ask et on the ﬁlter with fresh, clean oil. Screw the ﬁlter on b y hand until the g ask et contacts the oil ﬁlter adapter . Tighten 1/2 to 3/4 tur n more .

4. Add oil; refer to Adding Engine Oil.

7. Shut off the engine .

8. W ait 3 min utes and c hec k the oil lev el.

9. Add oil, if required, to bring the lev el to the upper hole on the dipstic k.

10. R e place the dipstic k and , ﬁller cap , and the front engine panel.

11. Chec k for leaks .

Important: Do not o v erﬁll the crankcase with oil because this may cause engine dama ge.

Changing the Engine Oil Filter

Chang e the engine oil ﬁlter as follo ws:

• After the ﬁrst 50 operating hours .

• Ev er y 200 hours after the ﬁrst 50 operating

hours .

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

Place a drip pan beneath the oil drip tra y to recei v e oil from the oil ﬁlter and oil passag es in the engine .

Figure 41

1. Oil lter 2. Right side of machine

Figure 42

1. Oil lter 3. Adapter

2. Gasket

2. T ur n the ﬁlter countercloc kwise to remo v e it ( Figure 41 and Figure 42 ).

Note: Dispose of the oil ﬁlter properly . R ecycle in accordance with local codes .

Page 38

Fuel System

Electrical System

Maintenance

Servicing the Fuel Filters

R e place the fuel ﬁlters after ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst, and re place them more frequently under extremely dusty or dir ty conditions .

Replacing the Fuel Filter

Ensure that an A uthorized Ser vice Dealer re places the fuel ﬁlter and any components for the fuel system.

Use of impr oper components can r esult in system f ailur e, fuel leaka ge and possible explosion.

• Ensur e that an Authoriz ed Ser vice Dealer r eplace the fuel ﬁlter and an y components f or the fuel system.

• Use onl y appr o v ed fuel lines, hose clamps and fuel ﬁlter s f or high pr essur e systems.

Maintenance

Servicing the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

Do not drink electr ol yte and a v oid contact with skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

Removing the Battery

Servicing the Fuel Tank

Do not attempt to drain the fuel tank because fuel line components require special tools to install them. Ensure that an A uthorized Ser vice Dealer drains the fuel tank and ser vices any components of the fuel system.

Batter y ter minals or metal tools could shor t a gainst metal machine components causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the machine.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the machine.

Page 39

8. Slide the h y draulic tank a w a y from the batter y .

Incor r ect batter y ca ble r outing could dama ge the machine and ca bles causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays Disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays R econnect the positi v e (r ed) batter y ca ble bef or e r econnecting the negati v e (black) ca ble.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Unlatc h the seat and tilt the seat up .

4. First disconnect the neg ati v e batter y cable from the neg ati v e (-) batter y ter minal ( Figure 43 ).

5. Slide the red ter minal boot off the positi v e (red) batter y ter minal. T hen remo v e the positi v e (red) batter y cable ( Figure 43 ).

9. R emo v e the batter y .

Figure 44

1. Battery

2. Hydraulic tank 5. Right side fuel tank

3. Bolts

4. Wing nut

Figure 43

1. Negative Battery Post

2. Positive Battery Post

3. Red (+) cable

4. Black (-) cable

6. R emo v e both wing n uts (1/4 inc h) securing the batter y clamp ( Figure 44 ).

7. R emo v e the tw o bolts holding the h y draulic tank in place ( Figure 44 ).

Installing the Battery

1. P osition batter y in the tra y with the ter minal posts opposite from the h y draulic tank ( Figure 44 ).

2. First, install the positi v e (red) batter y cable to positi v e (+) batter y ter minal.

3. T hen install the neg ati v e batter y cable and g round wire to the neg ati v e (-) batter y ter minal.

4. Secure the cables with 2 bolts (1/4 x 3/4 inc h), 2 w ashers (1/4 inc h), and 2 loc kn uts (1/4 inc h) ( Figure 43 ).

5. Slide the red ter minal boot onto the positi v e (red) batter y post.

6. Secure batter y with J-bolts , hold do wn clamp and 2 w ashers (1/4 inc h), and 2 wing n uts (1/4 inc h) ( Figure 44 ).

Page 40

Charging the Battery

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

Important: Al w ays k eep the batter y full y charged (1.265 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32°F (0°C).

1. Mak e sure the ﬁller caps are installed in batter y . Charg e batter y for 10 to 15 min utes at 25 to 30 amps or 30 min utes at 10 amps .

2. W hen the batter y is fully c harg ed, unplug the c harg er from the electrical outlet, then disconnect the c harg er leads from the batter y posts ( Figure 45 ).

c hec k the component/circuit for malfunction or a shor t.

Fuses:

• Ignition, F1-30 amp , blade-type

• Radiator F an, F2-40 amp , blade-type

1. Unlatc h the engine hood and raise the engine hood to g ain access to fuse holder ( Figure 46 ).

2. T o re place the fuses , pull out on the fuse to remo v e it.

3. Install a new fuse ( Figure 46 ).

3. Install the batter y in the mac hine and connect the batter y cables , refer to Installing the Batter y .

Note: Do not r un the mac hine with the batter y disconnected, electrical damag e ma y occur .

Figure 45

1. Positive Battery Post

2. Negative Battery Post

3. Red (+) Charger Lead

4. Black (-) Charger Lead

Figure 46

1. Left side fuel tank 3. Radiator fan-40amp

2. Ignition-30 amp

Servicing the Fuses

T he electrical system is protected b y fuses . It requires no maintenance; ho w ev er , if a fuse blo ws

Page 41

Drive System Maintenance

Adjusting the Tracking

T he mac hine has a knob for adjusting the trac king located under the seat.

Important: Adjust the handle neutral and h y draulic pump neutral bef or e adjusting the tracking . R efer to Adjusting the Handle Neutral in Contr ols System Maintenance , pa ge 48 and Adjusting the Hy draulic Pump Neutral in Hy draulic System Maintenance , pa ge 49 .

1. Push both control lev ers forw ard the same distance .

2. Chec k if the mac hine pulls to one side . If it does , stop the mac hine and set the parking brak e .

3. Unlatc h the seat and tilt the seat forw ard to access the trac king knob .

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

4. T o mak e the mac hine g o right, tur n the knob to w ards the rightside of the mac hine . R efer to Figure 47 .

5. T o mak e the mac hine g o left, tur n the knob to w ards the leftside of the mac hine . R efer to Figure 47 .

6. R e peat adjustment until the trac king is cor rect.

Figure 47

1. Tracking knob 4. Turn this way to track right

2. Hydraulic tank 5. Turn this way to track left

3. Hydraulic pumps

Checking the Tire Pressure

Chec k the pressure at the v alv e stem after ev er y 50 operating hours or monthly , whic hev er occurs ﬁrst ( Figure 48 ).

Maintain the air pressure in the rear tires at 12-14 psi (83-97 kP a). Unev en tire pressure can cause an unev en cut.

Note: T he front tires are semi-pneumatic tires and do not require air pressure maintenance .

Page 42

Figure 48

Checking the Wheel Hub Slotted Nut

Chec k after ev er y 500 operating hours .

T he slotted n ut needs to be tor qued to 125 ft-lb (170 N•m).

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the cotter pin.

4. T or que the slotted n ut to 125 ft-lb (170 N•m) ( Figure 49 ).

7. T or que the slotted n ut to 125 ft-lb . (170 N•m) ( Figure 49 ).

8. Tighten the n ut until the next set of slots line up with the hole in the shaft ( Figure 49 ).

9. R e place the cotter pin.

Adjusting the Caster Pivot Bearing

Chec k after ev er y 500 operating hours or at storag e , whic h ev er comes ﬁrst.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the dust cap from caster and tighten loc k n ut ( Figure 50 ).

4. Tighten the loc kn ut until the spring w ashers are ﬂat and then bac k off a 1/4 tur n to properly set the pre-load on the bearings ( Figure 50 ).

Important: Mak e sur e spring w asher s ar e installed cor r ectl y as sho wn in Figur e 50 .

5. Install the dust cap ( Figure 50 ).

Figure 49

1. Slotted Nut 3. Hole in threaded shaft

2. Two threads or less showing

4. Washer (if needed)

5. Chec k the distance from bottom of slot in n ut to inside edg e of hole . T w o threads or less should be sho wing ( Figure 49 ).

6. If more than tw o threads are sho wing remo v e n ut and install w asher betw een hub and n ut.

Figure 50

1. Spring Washers

2. Lock Nut

3. Dust Cap

Page 43

Servicing the Gear Box

Cooling System

Checking the Gear Box Oil Level

Use SAE 75W–90 Synthetic Gear Lube .

1. P ark the mac hine on a lev el surface .

2. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

4. R emo v e the side or rear plug on the g ear bo x. ( Figure 51 ).

5. T he oil should be up to the opening of the g ear bo x.

6. Add oil if needed to bring it to the cor rect lev el.

Maintenance

Servicing the Cooling System

Discharge of hot pr essuriz ed coolant or touching hot radiator and sur r ounding par ts can cause sev er e bur ns.

• Do not r emo v e the radiator cap when the engine is hot. Al w ays allo w the engine to cool at least 15 min utes or until the radiator cap is cool enough to touch without bur ning y our hand bef or e r emo ving the radiator cap .

• Do not touch radiator and sur r ounding par ts that ar e hot.

R otating shaft and f an can cause per sonal injur y .

Figure 51

1. Gear box 3. Rear plug

2. Side plug 4. Pulley

Changing the Gear Box Oil

• Do not operate the machine without the co v er s in place.

• K eep ﬁnger s, hands and clothing clear of r otating f an and dri v e shaft.

• Shut of f the engine and r emo v e the ignition k ey bef or e perf or ming maintenance.

Sw allo wing engine coolant can cause poisoning .

• Do not s w allo w engine coolant.

• K eep out of r each fr om childr en and pets.

Checking the Engine Coolant Level

Chec k the engine coolant lev el daily .

Chec k the cooling system hoses ev er y 100 hours .

Contact an A uthorized Ser vice Dealer to c hang e the g ear bo x oil.

Fluid T ype: 50/50 mix of extended life antifreeze/Dex-Cool® and w ater

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Cooling System Capacity: 156 ounces (4.6 l) Note: Do not open the radiator cap . Doing this

ma y induce air into the cooling system.

1. P osition the mac hine on a lev el surface , stop the engine , and set the parking brak e .

2. Unlatc h the seat and tilt the seat up .

3. With the engine cool, c hec k the o v erﬂo w bottle lev el. T he ﬂuid needs to be up to the bump on the outside of the o v erﬂo w bottle ( Figure 52 ).

4. If the coolant lev el is lo w , add a 50/50 mix of extended life antifreeze/Dex-Cool® and w ater to the o v erﬂo w bottle ( Figure 52 ).

5. Add the 50/50 coolant mix to the o v erﬂo w bottle and ﬁll it to the indicator line on the bottle ( Figure 52 ).

Figure 53

1. Hydraulic oil cooler 3. Radiator screen

2. Left rear tire

Figure 52

1. Antifreeze overow bottle 2. Indicator line on side of overow bottle

Cleaning the Engine Oil Cooler and Radiator Screen

Before eac h use , c hec k and clean the radiator screen and oil cooler . R emo v e any build-up of g rass , dir t or other debris from the oil cooler and radiator screen with compressed air ( Figure 53 ).

Changing the Engine Coolant

Ha v e an A uthorized Ser vice Dealer c hang e the engine coolant ev er y year .

Brake Maintenance

Adjusting the Parking Brake

1. Eng ag e the parking brak e , lev er up .

2. Measure the length of the spring . Measurement should be 2-1/2 inc h (64 mm) betw een the w ashers ( Figure 54 ).

3. If adjustment is necessar y , release the parking brak e , loosen the jam n ut belo w the spring and adjust the n ut directly belo w the spring ( Figure 54 ). T ur n the n ut until the cor rect measurement is obtained. T ur n the n ut cloc kwise to shor ten spring length and tur n counter -cloc kwise to lengthen the spring .

4. Tighten the tw o n uts tog ether .

5. Eng ag e the parking brak e , lev er up . Chec k the measurement of the spring ag ain.

6. If adjustment is necessar y , re peat the procedures abo v e .

7. R e peat on the opposite side of mac hine .

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1. Brake lever in engaged position

2. Spring 2–1/2 inch (64 mm)

Belt Maintenance

8. Install the belt guide on the spring loaded idler at a 45 deg ree angle as sho wn in Figure 56 .

9. Install the belt co v ers b y sliding the co v er into the tab , install the bolts , and close the latc hes ( Figure 55 ).

Figure 54

3. Adjusting nut and jam nut

Inspecting the Belts

Inspect all belts ev er y 100 hours .

Chec k belts for crac ks , fra yed edg es , bur n marks , or any other damag e . R e place damag ed belts .

Replacing the Mower Belt

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks and crac ks are signs of a w or n mo w er belt. R e place the mo w er belt if any of these conditions are evident.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the bolts holding the belt co v ers and remo v e the belt co v ers ( Figure 55 ).

4. R emo v e the spring and belt guide from the idler ar m.

Figure 55

1. Belt cover 3. Bolt

2. Latch 4. Insert slot into the tab

Figure 56

1. Mower belt 4. Belt guide

2. Mower spindle pulley 5. Gearbox pulley

3. Mower idler pulley

6. Spring

5. R emo v e the existing belt if needed.

6. Install the new belt around the mo w er pulleys and the g earbo x pulley under the engine ( Figure 56 ).

7. Install spring to the idler ar m ( Figure 56 ).

Replacing the PTO Drive Belt

Squealing when the belt is rotating, blades slipping when cutting g rass , fra yed belt edg es , bur n marks ,

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and crac ks are signs of a w or n PTO belt. R e place the mo w er belt if any of these conditions are evident.

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Tilt the seat forw ard, loosen the bolts and remo v e the front engine panel ( Figure 57 ).

Figure 58

1. PTO Drive belt 4. Spring loaded idler pulley

2. Clutch 5. Gear box

3. Spring

6. Clutch stop bracket

Figure 57

1. Knob 2. Front engine panel

4. R emo v e the spring from the idler ar m ( Figure 58 ).

5. R emo v e the clutc h stop brac k et.

6. R emo v e the old PTO dri v e belt.

7. Install the PTO dri v e belt around the clutc h pulley and the g earbo x pulley ( Figure 58 ).

8. Intall the clutc h stop brac k et.

9. Install the spring to the idler ar m ( Figure 58 ).

Replacing the Pump Drive Belt

Chec k pump dri v e belt for w ear after ev er y 50 hours of operation.

Note: R emo v e the PTO dri v e belt ﬁrst if the pump dri v e belt needs to be re placed.

1. Tilt the seat forw ard and remo v e the front engine panel.

2. R emo v e the PTO dri v e belt.

3. R emo v e the spring from the idler ar m ( Figure 59 ).

4. Install the new belt around the engine and h y dro pump pulley ( Figure 59 ).

5. Install the PTO dri v e belt.

6. Install the spring to the idler ar m ( Figure 59 ).

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Figure 59

1. Pump drive belt 3. Spring loaded idler pulley

2. Clutch

4. Spring

1. Oil cooler shield

2. Bolts

Figure 60

3. Engine straps

Replacing and Tensioning the Alternator Belt

Chec k the alter nator belt for w ear after ev er y 50 hours of operation.

Replacing the Alternator Belt

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R emo v e the 4 bolts holding the oil cooler shield to the rear frame ( Figure 60 ).

4. R emo v e the 3 bolts holding the engine straps to the side of the mac hine ( Figure 60 ).

5. R emo v e the 4 bolts holding the oil cooler and position the oil cooler to the side ( Figure 61 ).

6. R emo v e the 2 bolts holding the fan and fan plate to the mac hine ( Figure 61 ).

Figure 61

1. Oil cooler 3. Fan plate

2. Fan

4. Alternator belt

7. Loosen the bottom bolt and remo v e the upper bolt holding the alter nator and co v er ( Figure 62 ).

8. R otate the alter nator co v er to the side and remo v e the belt from the pulleys and alter nator .

9. Install a new belt around the pulleys and the alter nator ( Figure 62 ).

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10. Install the fan and fan plate to the mac hine with the 2 bolts previously remo v ed ( Figure 61 ).

11. Install the oil cooler with the 4 bolts previously remo v ed ( Figure 61 ).

12. Install the oil cooler shield and engine straps to the rear frame with the 4 bolts previously remo v ed ( Figure 60 ).

13. Install the engine straps to the side of the mac hine ( Figure 60 ).

14. Tighten the bottom bolt and install the upper bolt holding the alter nator and co v er ( Figure 62 ).

Tensioning the Alternator Belt

1. Place a handle betw een the alter nator and cylinder bloc k.

2. Adjust the alter nator to the outside until there is 1/4 to 11/32 inc h (7 to 9 mm) deﬂection in the belt betw een the engine and the alter nator pulleys with 22.1 lbs of force (10 kgf) ( Figure 62 ).

3. Tighten the alter nator bolts .

4. Chec k the deﬂection in the belt ag ain and adjust the belt if needed.

Figure 62

1. Alternator 4. Top bolt

2. Alternator belt 5. Bottom bolt

3. Deection, 1/4 to 11/32 inch (7 to 9 mm) with 22.1 lbs of force (10 kgf)

5. If the deﬂection is cor rect, tighten the bottom and upper bolt ( Figure 62 ).

Controls System Maintenance

Adjusting the Control Handle Neutral Position

If motion control lev ers do not align, or mo v e easily into the console notc h, adjustment is required. Adjust eac h lev er , spring and rod se parately .

Note: Motion control lev ers m ust be installed cor rectly . See Installing the Motion Control Lev ers in the set up instr uctions .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Unlatc h the seat and tilt the seat forw ard.

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4. Begin with either the left or right motion control lev er .

5. Mo v e the lev er to the neutral position but not loc k ed ( Figure 63 ).

6. Pull the lev er bac k until the clevis pin (on ar m belo w pi v ot shaft) contacts the end of the slot (just beginning to put pressure on the spring) ( Figure 63 ).

7. Chec k where the control lev er is relati v e to notc h in console ( Figure 63 ). It should be centered allo wing lev er to pi v ot outw ard to the neutral loc k position.

Figure 64

1. Height-of-cut lever 5. Adjustment bolt

2. Nut against yoke 6. Yoke

3. Jam Nut

4. Clevis pin in slot

7. Spring

Figure 63

1. Neutral locked position 3. Neutral potion

2. Control lever

8. If adjustment is needed, loosen the n ut and jam n ut ag ainst the y ok e ( Figure 64 ).

9. Apply slight rearw ard pressure on the motion control lev er , tur n the head of the adjustment bolt in the appropriate direction until the control lev er is centered in the neutral loc k position ( Figure 64 ).

Note: K ee ping rearw ard pressure on the lev er will k ee p the pin at the end of the slot and allo w the adjustment bolt to mo v e the lev er to the appropriate position.

10. Tighten the n ut and jam n ut ( Figure 64 ).

11. R e peat for the opposite side of the mac hine .

Hydraulic System Maintenance

Servicing the Hydraulic System

Checking the Hydraulic Fluid Level

Fluid T ype: Mobil 1 15W -50 synthetic motor oil or equi v alent synthetic oil.

Important: Use oil speciﬁed or equi v alent. Other ﬂuids could cause system dama ge.

Hy draulic System Oil Capacity: 132 ounces (3.9 l)

Chec k the h y draulic ﬂuid lev el:

• Before the engine is ﬁrst star ted.

• After the ﬁrst 8 operating hours .

• Ev er y 25 hours after the ﬁrst 8 operating hours .

Note: T here are tw o w a ys of c hec king the h y draulic oil. One is when the oil is w ar m and one is when the oil is cold. T he bafﬂe inside the tank has tw o lev els de pending if the oil is w ar m or cold.

1. P osition the mac hine on a lev el surface and set the parking brak e .

Page 50

2. Clean the area around ﬁller nec k of h y draulic tank ( Figure 65 ).

3. R emo v e the cap from the ﬁller nec k. Look inside to c hec k if there is ﬂuid in the reser v oir ( Figure 65 ).

4. If there is no ﬂuid, add ﬂuid to the reser v oir until it reac hes the cold lev el of the bafﬂe .

5. R un the mac hine at lo w idle for 15 min utes to allo w any air to purg e out of the system and w ar m the ﬂuid. R efer to Star ting and Stopping the Engine in Operation , pag e 16 .

6. R ec hec k the ﬂuid lev el while the ﬂuid is w ar m. T he ﬂuid should be betw een cold and hot.

7. If required, add ﬂuid to the h y draulic tank. Note: T he ﬂuid lev el should be to the top

of the hot lev el of the bafﬂe , when the ﬂuid is hot ( Figure 65 ).

8. Install cap on ﬁller nec k.

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• If h y draulic ﬂuid is injected into the skin it must be surgicall y r emo v ed within a few hour s by a doctor f amiliar with this type of injur y . Gang r ene may r esult if this is not done.

• K eep body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to h y draulic system.

Figure 65

1. Cap

2. Bafe 4. Hot uid level-full

3. Cold uid level-full

Replacing the Hydraulic Filter and Oil

Chang e the h y draulic ﬁlter and oil as follo ws:

• After the ﬁrst 25 operating hours .

• Chang e yearly after the ﬁrst 25 operating hours .

Use summer ﬁlter abo v e 32°F (0°C)

Use winter ﬁlter belo w 32°F (0°C)

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

Important: Do not substitute automoti v e oil ﬁlter or sev er e h y draulic system dama ge may r esult.

3. Place drain pan under ﬁlter , remo v e the old ﬁlter and wipe the ﬁlter adapter g ask et surface clean ( Figure 66 ).

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Figure 66

1. Hydraulic lter

4. R emo v e the righthand h y draulic line that comes into the adapter ( Figure 67 ).

5. Allo w the oil to drain out of the system into the drain pan.

6. Install the righthand h y draulic line to the adapter ( Figure 67 ).

both wheels will not dri v e , refer to Bleeding Hy draulic System.

13. R ec hec k the ﬂuid lev el while the ﬂuid is w ar m. T he ﬂuid should be betw een cold and hot.

14. If required, add ﬂuid to the h y draulic tank. Do not o v erﬁll.

Figure 68

1. Hydraulic lter 3. Adapter

2. Gasket

Figure 67

1. Righthand hydraulic line 3. Hydraulic tank

2. Hydraulic lter

7. Apply a thin coat to the r ubber g ask et on the re placement ﬁlter ( Figure 68 ).

8. Install the re placement h y draulic ﬁlter onto the ﬁlter adapter . Do not tighten.

9. Fill the h y draulic tank with h y draulic ﬂuid until the ﬂuid o v erﬂo ws the ﬁlter and then tur n the oil ﬁlter cloc kwise until the r ubber g ask et contacts the ﬁlter adapter , then tighten the ﬁlter an additional 1/2 tur n ( Figure 68 ).

10. Clean up any spilled ﬂuid.

11. Add ﬂuid to the cold lev el of the bafﬂe in the h y draulic tank.

12. Star t the engine and let it r un for about tw o min utes to purg e air from the system. Stop the engine and c hec k for leaks . If one or

Bleeding the Hydraulic System

T he traction system is self bleeding, ho w ev er , it ma y be necessar y to bleed the system if ﬂuid is c hang ed or after w ork is perfor med on the system.

1. Raise rear of the mac hine so wheels are off the g round and suppor t with jac k stands .

2. Star t the engine and r un at lo w idle speed. Eng ag e the lev er and traction on one side and spin the wheel b y hand.

3. W hen the wheel begins to spin on its o wn, k ee p it eng ag ed until wheel dri v es smoothly . (minim um 2 min utes)

4. Chec k h y draulic ﬂuid lev el and add as required to maintain proper lev el.

5. R e peat this procedure on the opposite wheel.

Checking the Hydraulic Hoses

After ev er y 100 operating hours , c hec k the h y draulic hoses for leaks , loose ﬁttings , kink ed lines , loose mounting suppor ts , w ear , w eather and c hemical deterioration. Mak e necessar y re pairs before operating .

Note: K ee p areas around the h y draulic system clean from g rass and debris build up .

Page 52

Hy draulic ﬂuid escaping under pr essur e can penetrate skin and cause injur y .

• If h y draulic ﬂuid is injected into the skin it must be surgicall y r emo v ed within a few hour s by a doctor f amiliar with this type of injur y . Gang r ene may r esult if this is not done.

Engine must be r unning so motion contr ol adjustment can be perf or med. Contact with mo ving par ts or hot surf aces may cause per sonal injur y .

K eep hands, feet, f ace, clothing and other body par ts a w ay fr om r otating par ts, muf ﬂer and other hot surf aces.

• K eep body and hands a w ay fr om pin hole leaks or nozzles that eject high pr essur e h y draulic ﬂuid.

• Use cardboard or paper to ﬁnd h y draulic leaks.

• Safel y r eliev e all pr essur e in the h y draulic system bef or e perf or ming an y w or k on the h y draulic system.

• Mak e sur e all h y draulic ﬂuid hoses and lines ar e in good condition and all h y draulic connections and ﬁttings ar e tight bef or e appl ying pr essur e to h y draulic system.

Setting the Hydraulic Pump Neutral Position

Note: Adjust the handle neutral ﬁrst. T hat needs

to be cor rect before the follo wing adjustment can be made .

T his adjustment m ust be made with dri v e wheels tur ning .

Mechanical or h y draulic jacks may f ail to suppor t machine and cause a serious injur y .

• Use jack stand when suppor ting machine.

1. Raise the frame and bloc k up the mac hine so dri v e wheels can rotate freely .

2. Disconnect the electrical connector from the seat safety switc h. T emporarily install a jumper wire across ter minals in the wiring har ness connector .

3. Unlatc h the seat and slide seat forw ard.

4. Disconnect the seat rod and tilt the seat fully forw ard.

Setting the Right-hand Hydraulic Pump Neutral Position

1. Star t the engine , open the throttle 1/2 w a y and release parking brak e . R efer to Star ting and Stopping the Engine in Operation , pag e 16 .

Note: T he motion control lev er m ust be in neutral while making any adjustments .

2. Adjust the pump rod length b y rotating the knob , in the appropriate direction, until the wheel is still or slightly cree ping in rev erse ( Figure 69 ).

3. Mo v e the motion control lev er forw ard and rev erse , then bac k to neutral. T he wheel m ust stop tur ning or slightly cree p in rev erse .

4. Open the throttle to fast. Mak e sure wheel remains stopped or slightly cree ps in rev erse , adjust if necessar y .

• Do not use h y draulic jacks.

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6. Tighten the loc kn uts at the ball joints ( Figure 70 ).

Figure 69

1. Tracking knob 4. Turn this way to track right

2. Hydraulic tank 5. Turn this way to track left

3. Hydraulic pumps

Setting the Left-hand Hydraulic Pump Neutral Position

1. Loosen the loc kn uts at the ball joints on the pump control rod ( Figure 70 ).

2. Star t the engine , open throttle 1/2 w a y and release parking brak e . R efer to Star ting and Stopping the Engine in Operation , pag e 16 .

Note: T he motion control lev er m ust be in neutral while making any adjustments .

Note: T he front n ut on the pump rod has left-hand threads .

3. Adjust the pump rod length b y rotating double n uts on rod, in the appropriate direction, until wheel is still or slightly cree ps in rev erse ( Figure 70 ).

4. Mo v e the motion control lev er forw ard and rev erse , then bac k to neutral. T he wheel m ust stop tur ning or slightly cree p in rev erse .

5. Open the throttle to fast. Mak e sure the wheel remains stopped or slightly cree ps in rev erse , adjust if necessar y .

Figure 70

1. Double nuts 4. Locknut

2. Pump rod 5. Ball joint

3. Adjustment bolt

6. Pumps

Electrical system will not perf or m pr oper safety shut of f with jumper wir e installed.

• R emo v e jumper wir e fr om wir e har ness connector and plug connector into seat s witch when adjustment is completed.

• Nev er operate this unit with jumper installed and seat s witch bypassed.

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

8. R emo v e the jumper wire from the wire har ness connector and plug the connector into the seat switc h.

9. Install the seat rod and lo w er the seat into position.

10. R emo v e the jac k stands .

Page 54

Mower Deck Maintenance

Leveling the Mower at Three Positions

Setting Up the Machine

1. P osition mo w er on a ﬂat surface .

2. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

3. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

1. Measure here from blade to hard surface

Figure 71

2. Measure at B and C

4. Chec k tire pressure of all four tires . If needed, adjust to 13 psi (90 kP a)

5. Lo w er the mo w er to the 3 inc h (76 mm) height-of-cut position.

6. Inspect the four c hains . T he c hains need to ha v e tension.

• If one rear c hain is loose , lo w er (loosen) the front suppor t ar m on the same side . R efer to Adjusting the F ront-to-R ear Mo w er Pitc h.

• If one front c hain is loose , raise (tighten) the front suppor t ar m for that c hain. R efer to Adjusting the F ront-to-R ear Mo w er Pitc h.

Leveling the Mower Side-to-Side

1. P osition the right blade front-to-rear ( Figure 71 ).

2. Measure the right blade at the B location, from a lev el surface to the cutting edg e of the blade tip ( Figure 71 ).

7. If the measurements at positions B or C are not cor rect, loosen the bolt attac hing the rear c hain to the rear suppor t ar m ( Figure 72 ).

8. Loosen the jam n ut under the rear suppor t ar m and adjust the adjustment bolt to g et a measurement of 3-1/8 to 3-1/4 inc hes ( Figure 72 ).

Note: It is recommended that both sides of the mo w er are adjusted the same distance .

9. Tighten the jam n ut under the rear suppor t ar m and tighten the bolt securing the c hain to the rear suppor t ar m.

10. Adjust the opposite side if needed.

3. R ecord this measurement. T his measurement needs to be 3-1/8 to 3-1/4 inc hes .

4. P osition the left blade front-to-rear ( Figure 71 ).

5. Measure the left blade at the C location ( Figure 71 ), from a lev el surface to the cutting edg e of the blade tip .

6. R ecord this measurement. T his measurement needs to be 3-1/8 to 3-1/4 inc hes .

Figure 72

1. Rear chain 5. Adjustment bolt

2. Rear support arm

3. Bolt

4. Jam Nut

6. Front swivel

7. Front support arm

Page 55

Adjusting the Front-to-Rear Mower Pitch

1. P osition the right blade front-to-rear ( Figure 73 ).

2. Measure the right blade at the A location, from a lev el surface to the cutting edg e of the blade tip( Figure 73 ).

Adjusting the Compression Spring

1. Raise the mo w er lift lev er to the transpor t position.

2. Chec k the distance betw een the tw o larg e w ashers , it needs to be 11-1/8 inc hes (28.2 cm) for 52 inc h mo w er dec ks and 10-1/2 inc hes (26.7 cm) for 60 inc h mo w er dec ks ( Figure 74 ).

3. Adjust this distance , b y loosening the spring jam n ut and tur ning the n ut in front of eac h spring ( Figure 74 ). T ur ning the n ut cloc kwise will shor ten the spring; counter -cloc kwise will lengthen the spring .

4. Loc k the n ut into position b y tightening the spring jam n ut ( Figure 74 ).

Figure 73

1. Measure here from blade to hard surface

2. Measure at A and B

3. R ecord this measurement.

4. Measure the right blade at the B location, from a lev el surface to the cutting edg e of the blade tip ( Figure 73 ).

5. R ecord this measurement.

6. T he mo w er blade should be a 1/4 to 3/8 inc h (6 to 10 mm) lo w er at position A than at position B ( Figure 73 ). If it is not cor rect, proceed to the follo wing ste ps .

Note: Both of the front swi v els need to be adjusted the same amount to maintain equal c hain tension.

7. Loosen the front swi v el jam n uts , at the front of the right and left swi v els , appro ximately a 1/2 inc h (13 mm) ( Figure 72 ).

8. Adjust the lift n uts on both the left and the right side of the mac hine to ac hiev e 1/4 to 3/8 inc h (6 to 10 mm) lo w er in front at A than in the rear at B ( Figure 72 ).

9. Tighten both swi v el jam n uts ag ainst the front swi v el to loc k the height.

10. Chec k to mak e sure there is equal tension on the c hains and adjust ag ain if needed.

Figure 74

1. 11–1/8 inch (28.2 cm) between the large washers for 52 inch mower decks

2. Front nut

3. Spring jam nut

4. Front swivel

5. Swivel jam nut

6. Lift nut

7. Front support arm

8. Large washer

9. 10-1/2 inch (26.7 cm) between the large washers for 60 inch mower decks

Servicing the Cutting Blades

Maintain shar p blades throughout the cutting season because shar p blades cut cleanly without tearing or shredding the g rass blades . T earing and shredding tur ns g rass bro wn at the edg es , whic h slo ws g ro wth and increases the c hance of disease .

Chec k the cutter blades daily for shar pness , and for any w ear or damag e . File do wn any nic ks and shar pen the blades as necessar y . If a blade is damag ed or w or n, re place it immediately with a

Page 56

g en uine T oro re placement blade . F or con v enient shar pening and re placement, y ou ma y w ant to k ee p extra blades on hand.

Checking for Bent Blades

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

A w or n or dama ged blade can br eak, and a piece of the blade could be thr o wn into the operator’ s or bystander’ s ar ea, r esulting in serious per sonal injur y or death.

• Inspect the blade periodicall y f or w ear or dama ge.

• R eplace a w or n or dama ged blade.

Inspect and c hec k the blades ev er y 8 hours .

Before Inspecting or Servicing the Blades

P ark the mac hine on a lev el surface , diseng ag e the blade control (PTO), and set the parking brak e . T ur n the ignition k ey to Off . R emo v e the k ey .

Inspecting the Blades

1. Inspect the cutting edg es ( Figure 75 ). If the edg es are not shar p or ha v e nic ks , remo v e and shar pen the blades . R efer to Shar pening the Blades .

2. Inspect the blades , especially the cur v ed area ( Figure 75 ). If y ou notice any damag e , w ear , or a slot for ming in this area ( Figure 75 ), immediately install a new blade .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. R otate the blades until the ends face forw ard and bac kw ard ( Figure 76 ). Measure from a lev el surface to the cutting edg e , position A , of the blades ( Figure 76 ). Note this dimension.

Figure 76

1. Measure here from blade to hard surface

2. Position A

4. R otate the opposite ends of the blades forw ard.

Figure 75

1. Cutting Edge 3. Wear/slot Forming

2. Curved Area

5. Measure from a lev el surface to the cutting edg e of the blades at the same position as in ste p 3 abo v e . T he difference betw een the dimensions obtained in ste ps 3 and 4 m ust not ex ceed 1/8 inc h (3 mm). If this dimension ex ceeds 1/8 inc h (3 mm), the blade is bent and m ust be re placed; refer to R emo ving the Blades and Installing the Blades .

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A blade that is bent or dama ged could br eak apar t and could seriousl y injur e or kill y ou or bystander s.

• Al w ays r eplace bent or dama ged blade with a new blade.

• Nev er ﬁle or cr eate shar p notches in the edges or surf aces of blade.

Removing the Blades

Blades m ust be re placed if a solid object is hit, if the blade is out of balance or is bent. T o ensure optim um perfor mance and contin ued safety confor mance of the mac hine , use g en uine T oro re placement blades . R e placement blades made b y other man ufacturers ma y result in non-confor mance with safety standards .

Figure 77

1. Sharpen at original angle

2. Chec k the balance of the blade b y putting it on a blade balancer ( Figure 78 ). If the blade sta ys in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, ﬁle some metal off the end of the sail area only ( Figure 79 ). R e peat this procedure until the blade is balanced.

Contact with a shar p blade can cause serious injur y .

W ear g lo v es or wrap shar p edges of the blade with a ra g .

1. Hold the blade end using a rag or thic kly-padded glo v e .

2. R emo v e the blade bolt, spring disk and blade from the spindle shaft ( Figure 79 ).

Sharpening the Blades

W hen shar pening blade, pieces of blade could be thr o wn and cause serious injur y .

W ear pr oper ey e pr otection when shar pening blade.

1. Use a ﬁle to shar pen the cutting edg e at both ends of the blade ( Figure 77 ). Maintain the original angle . T he blade retains its balance if the same amount of material is remo v ed from both cutting edg es .

Figure 78

1. Blade 2. Balancer

Installing the Blades

1. Install the blade onto the spindle shaft ( Figure 79 ).

Important: T he cur v ed par t of the blade must be pointing up w ard to w ard the inside of the mo w er to ensur e pr oper cutting .

2. Install the spring disk and blade bolt. T he spring disk cone m ust be installed to w ard the bolt head ( Figure 79 ). T or que the blade bolt to 85-110 ft-lb (115-150 N•m).

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Figure 79

1. Sail Area of Blade 4. Blade Bolt

2. Blade 5. Cone Towards Bolt Head

3. Spring Disk

Replacing the Grass Deector

Figure 80

1. Bolt 5. Spring installed

2. Spacer

3. Locknut 7. L end of spring, place

4. Spring

6. Grass Deector

behind deck edge before installing bolt

8. J hook end of spring

An unco v er ed discharge opening could allo w the la wn mo w er to thr o w objects in the operator’ s or bystander’ s dir ection and r esult in serious injur y . Also, contact with the blade could occur .

• Nev er operate the la wn mo w er unless y ou install a co v er plate, a mulch plate, or a g rass chute and catcher .

• Mak e sur e the g rass deﬂector is in the do wn position.

1. R emo v e the loc kn ut, bolt, spring and spacer holding the deﬂector to the pi v ot brac k ets ( Figure 80 ). R emo v e the damag ed or w or n g rass deﬂector .

2. Place the spacer and spring onto g rass deﬂector . Place the L end of spring behind dec k edg e .

Note: Mak e sure the L end of the spring is installed behind the dec k edg e before installing the bolt as sho wn in Figure 80 .

Cleaning

Cleaning Under the Mower

R emo v e the g rass buildup under the mo w er daily .

1. Diseng ag e the PTO , mo v e the motion control lev ers to the neutral loc k ed position and set the parking brak e .

2. Stop the engine , remo v e the k ey , and w ait for all mo ving par ts to stop before lea ving the operating position.

3. Raise the mo w er to the transpor t position.

Waste Disposal

Engine oil, batteries , h y draulic oil, and engine coolant are pollutants to the en vironment. Dispose of these according to y our state and local regulations .

3. Install the bolt and n ut. Place the J hook end of the spring around the g rass deﬂector ( Figure 80 ).

Important: T he g rass deﬂector must be a ble to lo w er do wn into position. Lift the deﬂector up to test that it lo w er s into the full do wn position.

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Storage

Cleaning and Storage

1. Diseng ag e the po w er tak e off (PTO), set the parking brak e , and tur n the ignition k ey to Off . R emo v e the k ey .

2. R emo v e g rass clippings , dir t, and g rime from the exter nal par ts of the entire mac hine , especially the engine and h y draulic system. Clean dir t and c haff from the outside of the engine cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not pr essur e w ash the machine. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, h y draulic pumps, and motor s.

3. Chec k the brak e; refer to Ser vicing the Brak e in Brak e Maintenance , pag e 44 .

4. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner in Engine Maintenance , pag e 33 .

5. Grease the mac hine; refer to Greasing and Lubrication in Lubrication , pag e 32 .

6. Chang e the crankcase oil; refer to Ser vicing the Engine Oil in Engine Maintenance , pag e 33 .

7. Chec k the tire pressure; refer to Chec king the Tire Pressure in Dri v e System Maintenance , pag e 41 .

8. Chang e the h y draulic ﬁlter; refer to Ser vicing the Hy draulic System in Hy draulic System Maintenance , pag e 49 .

A. Add a petroleum based

stabilizer/conditioner to fuel in the tank. F ollo w mixing instr uctions from the stabilizer man ufacturer . Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh fuel and used at all times .

B . R un the engine to distribute conditioned

fuel through the fuel system (5 min utes).

C . Stop the engine , allo w it to cool, and drain

the fuel tank; refer to Ser vicing the Fuel T ank in Fuel System Maintenance , pag e 38 .

D . R estar t the engine and r un it until it stops .

E. Dispose of fuel properly . R ecycle as per

local codes .

Important: Do not stor e sta biliz er/conditioned fuel o v er 90 days.

13. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed.

14. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

15. Store the mac hine in a clean, dr y g arag e or storag e area. R emo v e the k ey from the ignition switc h and k ee p it out of reac h of c hildren or other unauthorized users . Co v er the mac hine to protect it and k ee p it clean.

9. Charg e the batter y; refer to Ser vicing the Batter y in Electrical System Maintenance , pag e 38 .

10. Scrape any hea vy buildup of g rass and dir t from the underside of the mo w er , then w ash the mo w er with a g arden hose .

Note: R un the mac hine with the PTO eng ag ed and the engine at high idle for 2 to 5 min utes after w ashing .

11. Chec k the condition of the blades; refer to Ser vicing the Cutting Blades in Mo w er Dec k Maintenance , pag e 54 .

12. Pre pare the mac hine for storag e when non-use occurs o v er 30 da ys . Pre pare the mac hine for storag e as follo ws:

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Troubleshooting

Problem

The starter does not crank.

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

Possible Cause Corrective Action

1. The blade control (PTO) is engaged.

2. The parking brake is not on.

3. The operator is not seated.

4. The battery is dead. 4. Charge the battery.

5. The electrical connections are corroded or loose.

6. The fuse is blown. 6. Replace the fuse.

7. The relay or switch is defective.

1. The fuel tank is empty. 1. Fill the fuel tank with

2. The air cleaner is dirty. 2. Clean or replace the air

3. Dirt is in the fuel lter. 3. Replace the fuel lter.

4. Dirt, water, or stale fuel is in the fuel system.

1. Move the blade control (PTO) to the disengaged position.

2. Set the parking brake.

3. Sit on the seat.

5. Check the electrical connections for good contact.

7. Contact an Authorized Service Dealer.

fuel.

cleaner element.

4. Contact an Authorized Service Dealer.

The engine loses power.

The engine overheats.

1. The engine load is excessive.

2. The air cleaner is dirty. 2. Clean the air cleaner

3. The oil level in the crankcase is low.

4. The cooling ns and air passages above the engine are plugged.

5. The vent hole in the fuel cap is plugged.

6. Dirt is in the fuel lter. 6. Replace the fuel lter.

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

1. The engine load is excessive.

2. The oil level in the crankcase is low.

3. The cooling ns and air passages above the engine are plugged.

1. Reduce the ground speed.

element.

3. Add oil to the crankcase.

4. Remove the obstruction from the cooling ns and air passages.

5. Clean or replace the fuel cap.

7. Contact an Authorized Service Dealer.

1. Reduce the ground speed.

2. Add oil to the crankcase.

3. Remove the obstruction from the cooling ns and air passages.

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Problem

Possible Cause Corrective Action

The machine does not drive.

Abnormal vibration.

1. The by pass valve is not closed tight.

2. The drive or pump belt is worn, loose or broken.

3. The drive or pump belt is off a pulley.

4. The idler spring is broken or missing.

5. The hydraulic uid level is low or too hot.

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

2. The blade mounting bolt is loose.

3. The engine mounting bolts are loose.

4. The engine pulley, idler pulley, or blade pulley is loose.

5. The engine pulley is damaged.

6. The blade spindle is bent.

7. The motor mount is loose or worn.

1. Tighten the by pass valve.

2. Change the belt.

3. Change the belt.

4. Replace the spring.

5. Add hydraulic uid to the reservoir or let it cool down.

1. Install new cutting blade(s).

2. Tighten the blade mounting bolt.

3. Tighten the engine mounting bolts.

4. Tighten the appropriate pulley.

5. Contact an Authorized Service Dealer.

6. Contact an Authorized Service Dealer.

7. Contact an Authorized Service Dealer.

Uneven cutting height.

1. The cutting blade(s) is/are not sharp.

2. The cutting blade(s) is/are bent.

3. The mower deck is not level.

4. The underside of mower is dirty.

5. The tire pressure is not correct.

6. The blade spindle is bent.

1. Sharpen the blade(s).

2. Install new cutting blade(s).

3. Level the mower deck from side-to-side and front-to-rear.

4. Clean the underside of the mower.

5. Adjust the tire pressure.

6. Contact an Authorized Service Dealer.

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Problem

Possible Cause Corrective Action

The cutting blades do not rotate.

1. The drive belt is worn, loose or broken.

2. The drive belt is off pulley.

3. The mower deck belt is worn, loose or broken.

4. The mower deck belt came off a pulley.

5. The idler spring is broken or missing.

1. Check the belt tension.

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

3. Install a new mower deck belt.

4. Install mower deck belt and check the idler pulley, idler arm and spring for the correct position and function.

5. Replace the spring.

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Schematics

Wire Diagram (Rev. A)

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