Toro 74534TE, 74536TE Operator's Manual

FormNo.3371-914RevA
GrandStand
®
Mower
With91cmor102cmTURBOFORCE CuttingUnit
ModelNo.74534TE—SerialNo.312000001andUp
ModelNo.74536TE—SerialNo.312000001andUp
®
ThisproductcomplieswithallrelevantEuropean directives,fordetailspleaseseetheseparateproduct specicDeclarationofConformity(DOC)sheet.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Introduction
Thisrotary-blade,ridinglawnmowerisintended tobeusedbyprofessional,hiredoperatorsor residentialhomeowners.Itisdesignedprimarily forcuttinggrassonwell-maintainedlawnson residentialorcommercialproperties.Itisnot designedforcuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .T oro.comfor productandaccessoryinformation,helpndingadealer, ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts, oradditionalinformation,contactanAuthorized ServiceDealerorToroCustomerServiceandhave themodelandserialnumbersofyourproductready . Figure1identiesthelocationofthemodelandserial numbersontheproduct.Writethenumbersinthe spaceprovided.
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjury ordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythefollowingwords:
Dangersignalsanextremehazardthatwillcause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
Warningsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
Cautionsignalsahazardthatmaycauseminor ormoderateinjuryifyoudonotfollowthe recommendedprecautions.
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizesgeneral informationworthyofspecialattention.
1.Locationofthemodelandserialnumbers
©2011—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Figure1
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
Contents
Introduction.................................................................2
Safety...........................................................................4
GeneralLawnMowerSafety.................................4
ToroMowerSafety...............................................5
SoundPressure.....................................................6
SoundPower........................................................6
VibrationLevelforModel74534TE.....................6
VibrationLevelforModel74536TE.....................6
SlopeIndicator.....................................................8
SafetyandInstructionalDecals.............................9
ProductOverview......................................................14
Controls.............................................................14
Specications.....................................................15
Operation...................................................................16
AddingFuel.......................................................16
CheckingtheEngineOilLevel............................17
BreakingInaNewMachine................................17
ThinkSafetyFirst...............................................17
OperatingtheParkingBrake...............................17
OperatingtheMowerBladeControlSwitch
(PTO)............................................................18
OperatingtheThrottle.......................................18
OperatingtheChoke..........................................18
OperatingtheIgnitionSwitch.............................19
UsingtheSpeedControlLever...........................19
UsingtheFuelShut-OffValve............................19
StartingandStoppingtheEngine........................20
TheSafetyInterlockSystem................................21
OperatingthePlatform......................................22
DrivingForwardorBackward.............................23
StoppingtheMachine.........................................24
PushingtheMachinebyHand.............................24
TransportingMachines.......................................25
LoadingMachines..............................................25
SideDischargingorMulchingtheGrass..............26
AdjustingtheHeight-of-Cut...............................26
AdjustingtheFlowBafe...................................27
PositioningtheFlowBafe.................................27
UsingCounterweights........................................28
Maintenance...............................................................29
RecommendedMaintenanceSchedule(s)................29
PremaintenanceProcedures....................................30
RaisingtheMowerforAccess.............................30
ReleasetheCushionforRearAccess...................31
Lubrication.............................................................32
HowtoGrease...................................................32
LubricatingtheMachine.....................................32
GreasingtheFrontCasterPivots.........................33
LubricatetheCasterWheelHubs........................33
EngineMaintenance...............................................34
ServicingtheAirCleaner....................................34
ServicingtheEngineOil.....................................35
ServicingtheSparkPlug.....................................37
FuelSystemMaintenance.......................................39
DrainingtheFuelTank.......................................39
ServicingtheFuelFilter......................................39
ElectricalSystemMaintenance................................40
ServicingtheBattery...........................................40
ServicingtheFuses.............................................41
DriveSystemMaintenance.....................................42
AdjustingtheTracking.......................................42
CheckingtheTirePressure.................................43
AdjustingtheCasterPivotBearing......................43
AdjustingtheElectricClutch..............................44
CoolingSystemMaintenance..................................45
CleaningtheAirIntakeScreen............................45
CleaningtheCoolingSystem...............................45
BrakeMaintenance.................................................46
ServicingtheBrake.............................................46
BeltMaintenance....................................................47
CheckingtheBelts..............................................47
ReplacingtheMowerDeckBeltfor91cm
Mowers..........................................................47
ReplacingtheMowerDeckBeltsfor102cm
Mowers..........................................................47
ReplacingtheRightMowerDeckBelt.................47
ReplacingtheLeftMowerDeckBelt...................48
ReplacingthePumpDriveBelt...........................48
ControlsSystemMaintenance.................................49
AdjustingtheMotionControlHandle
Positions........................................................49
HydraulicSystemMaintenance...............................52
ServicingtheHydraulicSystem...........................52
MowerDeckMaintenance......................................55
ServicingtheCuttingBlades...............................55
LevelingtheMower............................................56
ReplacingtheGrassDeector.............................60
Cleaning.................................................................61
CleaningUndertheMower.................................61
WasteDisposal...................................................61
Storage.......................................................................61
CleaningandStorage..........................................61
Troubleshooting.........................................................63
Schematics.................................................................65
3
Safety
Improperlyusingormaintainingthismowercan resultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructions.
Torodesignedandtestedthismowerforreasonablysafe service;however,failuretocomplywiththefollowing instructionsmayresultinpersonalinjury.
Toensuremaximumsafety,bestperformance,and togainknowledgeoftheproduct,itisessential thatyouandanyotheroperatorofthemowerread andunderstandthecontentsofthismanualbefore theengineiseverstarted.Payparticularattention tothesafetyalertsymbol( Caution,Warning,orDanger—“personalsafety instruction.”Readandunderstandtheinstruction becauseithastodowithsafety .Failuretocomply withtheinstructionmayresultinpersonalinjury.
GeneralLawnMowerSafety
Thefollowinginstructionshavebeenadaptedfromthe standardEN836:1997.
Figure2)whichmeans
inadequatebraking
thetypeofmachineisunsuitableforit'stask
lackofawarenessoftheeffectofground
conditions,especiallyslopes
incorrectloaddistribution
Gasoline
WARNING-Gasolineishighlyammable.Takethe followingprecautions.
Storefuelincontainersspecicallydesignedforthis purpose.
Refueloutdoorsonlyanddonotsmokewhile refueling.
Addfuelbeforestartingtheengine.Neverremove thecapofthefueltankoraddgasolinewhilethe engineisrunningorwhentheengineishot.
Ifgasolineisspilled,donotattempttostartthe enginebutmovethemowerawayfromtheareaof spillageandavoidcreatinganysourceofignition untilgasolinevaporshavedissipated.
Replaceallfueltankandcontainercapssecurely.
Thiscuttingmachineiscapableofamputatinghands andfeetandthrowingobjects.Failuretoobservethe followingsafetyinstructionscouldresultinserious injuryordeath.
Training
Readtheinstructionscarefully.Befamiliarwiththe controlsandtheproperuseoftheequipment.
Neverallowchildrenorpeopleunfamiliarwiththese instructionstousethemower.Localregulationscan restricttheageoftheoperator.
Keepinmindthattheoperatororuserisresponsible foraccidentsorhazardsoccurringtootherpeopleor theirproperty.
Understandexplanationsforallpictogramsusedon themowerorintheinstructions.
Donotcarrypassengers.
Alloperatorsshouldseekandobtainprofessional andpracticalinstruction.
Usecareandconcentrationwhenworkingwith machines.
Thecontrolofamachineonaslopewillnotbe regainedbytheapplicationofthebrake.
Themainreasonsforlossofcontrolare:
insufcientwheelgrip
beingdriventoofast
Preparation
Whilemowing,alwayswearsubstantialfootwearand longtrousers.Donotoperatetheequipmentwhen barefootorwearingopensandals.
Thoroughlyinspecttheareawheretheequipmentis tobeusedandremoveallstones,sticks,wires,bones andotherforeignobjects.
Beforeusing,alwaysvisuallyinspecttoseethat guards,andsafetydevices,suchasdeectorsand/or grasscatchers,areinplaceandworkingcorrectly.
Beforeusing,alwaysvisuallyinspecttoseethatthe blades,bladeboltsandcutterassemblyarenotworn ordamaged.Replacewornordamagedbladesand boltsinsetstopreservebalance.
Starting
Disengageallbladeanddriveclutchesandshiftinto neutralbeforestartingtheengine.
Starttheengineorswitchonthemotorcarefully accordingtoinstructionsandwithfeetwellaway fromtheblade(s)andnotinfrontofthedischarge chute.
Operation
Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
4
Nevermowwhilepeople,especiallychildren,orpets arenearby .
Mowonlyindaylightoringoodarticiallight.
Avoidoperatingthelawnmowerinwetgrass,where feasible.
Stayalertforholesintheterrainandotherhidden hazards.
Neverdirectdischargeofmaterialtowards bystanders.
Donotputhandsorfeetnearorunderrotatingparts. Keepclearofthedischargeopeningatalltimes.
Useextremecautionwhenreversingorpullinga pedestriancontrolledlawnmowertowardsyou.
Walk,neverrun.
Slopes:
Donotmowexcessivelysteepslopes.Donot
mowslopesgreaterthan15degrees.
Exerciseextremecautionwhenonslopes.
Mowacrossthefaceofslopes,neverupand
downandexerciseextremecautionwhen changingdirectiononslopes.
Alwaysbesureofyourfootingonslopes.
Uselowthrottlesettingswhenengagingthe traction-clutch,especiallyinhighgears.Reduce speedonslopesandinsharpturnstoprevent overturningorlossofcontrol.
Stopthebladewhencrossingsurfacesotherthan grassandwhentransportingthelawnmowertoand fromtheareatobemowed.
Donotoperatetheengineinaconnedspacewhere dangerouscarbonmonoxidefumescancollect.
Stoptheengine
wheneveryouleavethelawnmower.
beforerefueling.
beforeremovingthegrasscatcher.
Stoptheengineanddisconnectthespark-plugwire orturnoffandremovethekey.
beforeclearingblockagesoruncloggingchute.
beforechecking,cleaningorworkingonthelawn
mower.
afterstrikingaforeignobject,inspectthelawn
mowerfordamageandmakerepairsbefore restartingandoperatingthelawnmower.
iflawnmowerstartstovibrateabnormally(check
immediately).
Watchoutfortrafcwhencrossingornearroadways.
Beforeleavingtheoperator'sposition
disengagethepowertake-offandlowerthe
attachments.
changeintoneutralandsettheparkingbrake.
stoptheengineandremovethekey.
MaintenanceandStorage
Keepallnuts,boltsandscrewstighttobesurethe equipmentisinsafeworkingcondition.
Donotusepressurecleaningequipmentonmachine.
Neverstoretheequipmentwithgasolineinthetank andinsideabuildingwherefumescanreachanopen ameorspark.
Allowtheenginetocoolbeforestoringinany enclosure.
Toreducetherehazard,keeptheengine,silencer, batterycompartmentandgasolinestoragefreeof grass,leaves,orexcessivegrease.
Checkgrasscatchercomponentsandthedischarge guardfrequentlyandreplacewithmanufacturer's recommendedparts,whennecessary.
Replacewornordamagedpartsforsafety .
Replacefaultysilencers.
Ifthefueltankhastobedrained,dothisoutdoors.
Donotchangetheenginegovernorsettingsor overspeedtheengine.Operatinganengineat excessivespeedcanincreasethehazardofpersonal injury.
Onmultibladedlawnmowers,takecareasrotating oneblademaycauseotherstorotate.
Becarefulduringadjustmentofthelawnmowerto prevententrapmentofthengersbetweenmoving bladesandxedpartsofthelawnmower.
Toensurethebestperformanceandsafety ,
purchaseonlygenuineT ororeplacementparts andaccessories.Donotuse accessories;theymaycauseasafetyhazard.
will t
partsand
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatchingcut grass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
5
GeneralOperation
Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.
Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.
UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.
Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforeoperating underanyobjectsanddonotcontactthem.
Slowdownbeforemakingturnsanduseextra caution.
Usecautionwhenridingtheplatformovercurbs, rocks,roots,orotherobstructions.
Lookbehindanddownbeforebackinguptobesure ofaclearpath.Useextracarewhenoperationin reverse.
Neverjerkthecontrols;useasteadymotion.
Donotcarrypassengers.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.
Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.
Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.
Usecautionneardrop-offs,ditches,orembankments. Themachinecouldsuddenlyturnoverifawheel goesovertheedgeofaclifforditch,orifanedge cavesin.
Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.
Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.
Mowslopessidetoside.
Service
Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.
Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.
Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.
Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.
Checkbrakeoperationfrequently.Adjustandservice asrequired.
SoundPressure
Model74534TEhasasoundpressurelevelatthe operator’searof88dBA,whichincludesanUncertainty Value(K)of1dBA.
Model74536TEhasasoundpressurelevelatthe operator’searof86dBA,whichincludesanUncertainty Value(K)of1dBA.
Thesoundpressurelevelwasdeterminedaccordingto theproceduresoutlinedinEN836.
SoundPower
Model74534TEhasaguaranteedsoundpowerlevel of100dBA,whichincludesanUncertaintyValue(K) of1dBA.
Model74536TEhasaguaranteedsoundpowerlevel of100dBA,whichincludesanUncertaintyValue(K) of1dBA.
Thesoundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinISO11094.
VibrationLevelforModel 74534TE
Hand-Arm
Measuredvibrationlevelforrighthand=0.8m/s
Measuredvibrationlevelforlefthand=0.6m/s
UncertaintyValue(K)=0.4m/s
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN836.
WholeBody
Measuredvibrationlevel=0.79m/s
UncertaintyValue(K)=0.39m/s
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN836.
2
2
2
2
VibrationLevelforModel 74536TE
Hand-Arm
Measuredvibrationlevelforrighthand=1.1m/s
2
2
6
Measuredvibrationlevelforlefthand=1.1m/s
2
UncertaintyValue(K)=0.6m/s
2
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN836.
WholeBody
Measuredvibrationlevel=0.79m/s
UncertaintyValue(K)=0.39m/s
2
2
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN836.
7
SlopeIndicator
G015791
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
8
SafetyandInstructional Decals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
93-7010
1.Thrownobjecthazard—keepbystandersasafedistance fromthemachine.
2.Thrownobjecthazard,mower—keepthedeectorinplace.
3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts.
93-7818
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto115-149N-m(85-110ft-lb).
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator's
Manual.
6.Keepbystandersasafe
7.Weareyeprotection;
8.Batteryacidcancause
10.Containslead;donot
106-5517
1.Warning—donottouchthehotsurface.
distancefromthebattery.
explosivegasescan causeblindnessandother injuries
blindnessorsevereburns.
withwaterandgetmedical helpfast.
discard.
Manufacturer'sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
9
110-2067
115-4212
120-6447
1.Tippinghazard—donotmowupanddownslopesgreater than10degrees,donotmowacrossslopesgreaterthan 15degrees.
1.Hydraulicoillevel3.Warning—donottouchthe hotsurface.
2.ReadtheOperator's
Manual.
116-3290
1.Interval
2.PowerT ake-off(PTO)
3.Parkingbrake
4.Neutral
5.Operatorpresenceswitch
6.Battery
115-4186
116-3267
10
119-0217
1.Warning—stoptheengine;stayawayfrommovingparts;
keepallguardsandshieldsinplace.
119-1854
1.Adjustmentknobfortractiondrivespeed.
119-0186
91cmMowerDeck
1.Beltrouting
119-2317
1.Height-of-cut(inches)
119-0187
102cmMowerDeck
1.Beltrouting
11
117-0454
1.Tractioncontrol
2.Fast4.Neutral
3.Slow
5.Reverse
6.PowerT ake-off (PTO)—disengage
7.Operatorpresenceswitch
117–3626
1.Warning—readtheOperator'sManual.5.Thrownobjecthazard—keepbystandersasafedistancefrom
2.Warning—donotoperatethismachineunlessyouaretrained.6.Warning—engagetheparkingbrake,stoptheengine
3.Thrownobjecthazard—keepdeectorinplace.
4.Cutting,dismembermenthazardofhandorfoot—stayaway frommovingpartsandkeepallguardsandshieldsinplace.
themachine.
andremovethesparkplugwirebeforeperformingany maintenanceonthemachine.
7.Warning—engagetheparkingbrakeandstoptheengine beforeleavingthemachine.
8.Slidingandlossofcontrolhazard—donotoperatethe machineneardrop-offsorwater;keepasafedistancefrom drop-offs.
1.Parkingbrake—disengaged4.Fast
2.Parkingbrake—engaged
3.Drivespeed
119-0234
5.Continuousvariablesetting8.PTO—disengaged
6.Slow
12
7.PTO—engaged
9.Enginespeed
119–0241
1.ReadtheOperator'sManualbefore performinganymaintenance.
2.Checkthedrivewheeltirepressure every50hours
3.Lubricateevery50hours
4.Lubricatethecasterwheelevery500 hours
5.Checkthehydraulicoilevery50hours
6.Checktheengineoilevery8hours
13
ProductOverview
g012564
1
7
2
8
3
9
4
10
5
11
6
12
Figure4
1.Sidedischargechute
2.Battery
3.Engine9.Hydraulictank
4.Fueltank10.Mowerdeck
5.Controls
6.Motioncontrollevers
7.Manualtube
8.Platform(downposition)
11.Frontcasterwheel
12.Operatorcushion
Figure5
1.Fuelcap7.Hourmeter
2.Height-of-cutlever8.Choke
3.Bladecontrolswitch(PTO)
4.Rightmotioncontrollever
5.Leftmotioncontrollever
6.Parkingbrakelever12.Throttlecontrol
9.Ignitionswitch
10.Speedcontrollever
11.Fuelgauge
HourMeter
Controls
Becomefamiliarwithallthecontrols(Figure5)before youstarttheengineandoperatethemachine.
Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance
Figure6).
(
FuelGauge
Thefuelgaugeislocatedonthetop,middleofthetank (Figure5).
SafetyInterlockIndicators
Therearesymbolsonthehourmeterandindicatewith ablacktrianglethattheinterlockcomponentisinthe correctposition(
Figure6).
BatteryIndicatorLight
IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure6).
14
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
Figure6
1.Safetyinterlocksymbols
2.Batterylight
3.Hourmeter
SpeedControlLever
Thismachinehasavariablespeedcontrol.Thiscontrols howfastorslowthemachinewilltravelwiththemotion controlleverspushedallthewayforward.
Note:Thenumbersnexttothespeedcontrolare anapproximatemaximummilesperhour(mph)the machinewilltravel.
ThrottleControl
ThethrottlecontrolisvariablebetweenFastandSlow.
Choke
Usethechoketostartacoldengine.
BladeControlSwitch(PTO)
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
Model74534TE
Widthwithdeectordown51.62inches(131.1cm)
Lengthwithplatformdown74inches(188cm)
Lengthwithplatformup61inches(155cm)
Height
Weight
Model74536TE
Widthwithdeectordown55.75inches(141.6cm)
Lengthwithplatformdown70inches(177.8cm)
Lengthwithplatformup57inches(144.8cm)
Height
Weight
48inches(121.9cm)
756(343kg)
48inches(121.9cm)
773(350.6kg)
Thebladecontrolswitch(PTO)isusedtoengage theelectricclutchtodrivethemowerbladeswiththe rightsidemotioncontrolleverinthecenter,un-locked position.Pulltheswitchuptoengagethebladesand release.Todisengagetheblades,pushthebladecontrol switch(PTO)downormoveorreleasetherightside motioncontrolleverintotheneutrallockposition.
IgnitionSwitch
Thisswitchisusedtostartthemowerengineandhas threepositions:Off,RunandStart.
MotionControlLevers
Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.
FuelShut-offValve
Closethefuelshut-offvalve(locatedbehindthe operatorcushionontherighthandsideoffueltank) whentransportingorstoringthemower.
15
Operation
AddingFuel
Forbestresults,useonlyclean,fresh,unleaded gasolinewithanoctaneratingof87orhigher ((R+M)/2ratingmethod).
Oxygenatedfuelwithupto10%ethanolor15% MTBEbyvolumeisacceptable.
DoNotuseethanolblendsofgasoline(suchasE15 orE85)withmorethan10%ethanolbyvolume. Performanceproblemsand/orenginedamagemay resultwhichmaynotbecoveredunderwarranty.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.
DoNotusegasolinecontainingmethanol.
DoNotstorefueleitherinthefueltankorfuel containersoverthewinterunlessafuelstabilizeris used.
DoNotaddoiltogasoline.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipeup anygasolinethatspills.
Neverllthefueltankinsideanenclosedtrailer.
Donotllthefueltankcompletelyfull.Fill thefueltanktothebottomofthellerneck. Theemptyspaceinthetankallowsgasolineto expand.Overllingmayresultinfuelleakage ordamagetotheengineoremissionsystem(if equipped).
Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.
Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.
Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
WARNING
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.
Avoidprolongedbreathingofvapors.
Keepfaceawayfromnozzleandgastankor conditioneropening .
Keepgasawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.
Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
Cleanstheenginewhileitruns
Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting
Important:Donotusefueladditives containingmethanolorethanol.
Addthecorrectamountofgasstabilizer/conditioner tothegas.
16
Note:Afuelstabilizer/conditionerismost
g012698
2
4
3
G012565
1
5
effectivewhenmixedwithfreshgasoline.To minimizethechanceofvarnishdepositsinthefuel system,usefuelstabilizeratalltimes.
CheckingtheEngineOilLevel
Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelinEngineMaintenance.
FillingtheFuelTank
Note:Donotllthefueltankcompletelyfull.Fillthe
fueltanktothebottomofthellerneck.Theempty spaceinthetankallowsthegasolinetoexpand.
1.Parkthemachineonlevelground.
2.Shuttheengineoffandsettheparkingbrake.
3.Cleanaroundthefueltankcap.
4.Fillthefueltanktothebottomofthellerneck. Ensurethereisemptyspaceinthetanktoallowthe gasolinetoexpand(
Figure7).
Note:Determinetheleftandrightsidesofthe machinefromthenormaloperatingposition.
BreakingInaNewMachine
Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew, placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.
ThinkSafetyFirst
Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator'searandcancausehearing lossthroughextendedperiodsofexposure.
Figure7
Wearhearingprotectionwhenoperatingthis machine.
OperatingtheParkingBrake
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse,check theparkingbrakeforproperoperation.
Iftheparkingbrakedoesnotholdsecurely,adjustit. RefertoServicingtheParkingBrake.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileit isunattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
SettingtheParkingBrake
Pulltheparkingbrakeleverrearwardtotheengaged position(Figure8).
17
Figure8
g012781
g012782
g012895
G008946
Figure10
1.Parkingbrakeengaged2.Parkingbrakereleased
ReleasingtheParkingBrake
Pushtheparkingbrakeleverforward.
OperatingtheMowerBlade ControlSwitch(PTO)
Thebladecontrolswitch(PTO)isusedinconjunction withtherightsidemotioncontrollevertoengageand disengagethemowerblades.
EngagingtheMowerBlades(PTO)
1.Toengagethemowerblades,movetherightside motioncontrollevertothecenter,un-locked position.
2.Pullthebladecontrolswitch(PTO)upandrelease itwhileholdingdowntherightsidemotioncontrol leverinthecenter,un-lockedposition.
Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.
Figure11
OperatingtheThrottle
ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure12).
Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).
Figure9
DisengagingtheMowerBlades(PTO)
Thefollowingaretwooptionsfordisengagingthe mowerblades.
Pushthebladecontrolswitch(PTO)downtothe offposition.
Figure12
OperatingtheChoke
Usethechoketostartacoldengine.
1.Iftheengineiscold,usethechoketostartthe engine.
2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(Figure13).
3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure13).
18
G008959
1
2
START
RUN
STOP
G008947
UsingtheSpeedControlLever
Thismachinehasaspeedcontrolleverthatsets themaximumgroundspeedofthemachine.This canbeadjustedtotheoperator'sdesiredspeed.It isrecommendedtousetheslowestspeedfornew operator's.
Note:Thenumbersnexttothespeedcontrolarean approximatemilesperhour(mph)themachinewill travel.
1.Movethespeedcontrollevertosetthedesired speed.
Fullforwardhasquickresponseandmaximum speed.
Fullrearwardhassmoothresponseandslower speed.
Figure13
1.On2.Off
OperatingtheIgnitionSwitch
1.TurntheignitionkeytotheStartposition (Figure14).Whentheenginesstarts,releasethekey.
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely .
2.Movethecontrolleverstodrivethemachine.The controlleversmaybepushedforwardtothefront referencebarwhilethemaximumspeedofthe machineissetbythespeedcontrollever.
Figure15
UsingtheFuelShut-OffValve
Thefuelshut-offvalveislocatedbehindtherightside
Figure14
2.Turntheignitionkeytothestoppositiontostop theengine.
oftheoperatorcushion.
Closethefuelshut-offvalvefortransport,maintenance, andstorage(Figure16).
Ensurethefuelshut-offvalveisopenwhenstarting theengine.
19
g012703
G008948
1
2
Figure16
START
RUN
STOP
G008947
1.On2.Off
StartingandStoppingthe Engine
StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
3.Movetherightmotioncontrollevertoneutral lockedposition.
4.Settheparkingbrake;refertoSettingtheParking Brake.
Figure17
7.TurntheignitionkeytotheStartposition (Figure14).Whentheenginesstarts,releasethekey.
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely .
5.Movethebladecontrolswitch(PTO)totheOff position.
6.MovethethrottlelevermidwaybetweentheSlow andFastpositions.
1.Off3.Start
2.Run
Figure18
Note:Awarmorhotenginemaynotrequire
choking.
20
StoppingtheEngine
TheSafetyInterlockSystem
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.
Donottamperwiththeinterlockswitches.
Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
UnderstandingtheSafetyInterlock System
Thesafetyinterlocksystemisdesignedtopreventthe mowerbladesfromrotatingunless:
Therightsidemotioncontrolleverismovedtothe center,un-lockedposition.
Thebladecontrolswitch(PTO)ispulledon.
Thesafetyinterlocksystemisdesignedtostopthe mowerbladesifyoumoveorreleasetherightside motioncontrolleverintotheneutrallockposition.
Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglewilllightupinthecorrespondingsquare.
Figure19
Important:Makesurefuelshutoffvalveisclosed
beforetransportingorstoringthemachine,asfuel leakagemayoccur.Beforestoringthemachine, pullwireoffsparkplug(s)topreventpossibilityof accidentalstarting.
Figure20
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
TestingtheSafetyInterlockSystem
ServiceInterval:Beforeeachuseordaily
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.
Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately .
1.Starttheengine;refertoStartingandStoppingthe Engine.
2.Settheparkingbrake.
21
3.Movetherightsidemotioncontrollevertothe center,un-lockedposition.Thebladesshould
notrotate.
4.Movethemotioncontrolleversforward.The engineshouldkill.
5.Starttheengineandreleasetheparkingbrake.
6.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
7.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.
8.Moveorreleasetherightsidemotioncontrollever intotheneutrallockposition.Thebladesshould
stoprotatingandtheenginecontinuestorun.
9.Pushthebladecontrolswitchdownandmove therightsidemotioncontrollevertothecenter, un-lockedposition.
10.Continueholdingtherightsidemotioncontrollever inthecenter,un-lockedpositionandpulluponthe bladecontrolswitch(PTO)andrelease.Theclutch shouldengageandthemowerbladesbeginrotating.
11.Pushthebladecontrolswitch(PTO)downtothe offposition.Thebladesshouldstoprotating.
12.Withtheenginerunning,pullupthebladecontrol switch(PTO)andreleasewithoutholdingright sidemotioncontrollevertothecenter,un-locked position.Thebladesshouldnotrotate.
WARNING
Theoperatorplatformisheavyandmaycause injurywhenloweringandraisingtheoperator platform.Theplatformmaysuddenlydropifnot supportedwhenthelatchpinispulledout.
Donotputhandsorngersintheplatform pivotareawhenloweringorraisingtheoperator platform.
Makesuretheplatformissupportedwhenthe latchpinispulledout.
Makesurethelatchsecurestheplatformwhen foldingitintheupposition.Pushittight againstthecushionforthelatchpintolock intoplace.
Keepbystandersawaywhenraisingorlowering theplatform.
OperatingtheMachinewiththe PlatformUp
Operatingthemachinewiththeplatformupis recommendedwhen:
Mowingneardrop-off's
Mowingsmallareaswherethemachineistoolong
Areaswithlowoverhangingbranchesorobstacles
Loadingthemachinefortransport
Drivingupslopes
Toraisetheplatform,pullthebackoftheplatformup sothelatchpinlocksitintoplace.Pushtheplatform tightagainstthecushionforthelatchpintolockinto place.
OperatingtheMachinewiththe PlatformDown
Operatingthemachinewiththeplatformdownis recommendedwhen:
Mowingmostareas
Drivingacrossslopes
Drivingdownslopes
Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatchpin andthenpulltheknoboutandlowertheplatform. Makesuretoholdontotheplatformwhenreleasing thelatch.
OperatingthePlatform
Themachinecanbeusedwiththeplatformintheup ordownposition.Itistheoperator'spreferenceon whichpositiontouse.
22
1.Platformup
g012570
4
5
1
2
3
2 4
2.Platformdown
Figure21
3.Pulltheknobouttorelease theplatform
1.Frontreferencebar
2.Leftcontrollever
3.Rearreferencebar
Figure22
4.Rightcontrollever
5.Rightcontrolleverinthe neutrallockposition
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
CAUTION
Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.
Slowthemachinedownbeforemakingsharpturns.
DrivingForward
1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
2.Togoforward,movethespeedcontrollevertothe desiredspeed.
3.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
4.Slowlypushthemotioncontrolleversforward (Figure23).
Note:Theenginewillkillifamotioncontrollever ismovedwiththeparkingbrakeengaged.
Thefartheryoumovethemotioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.
Tostop,pullthemotioncontrolleversbacktothe neutralposition.
23
Figure23
Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
PushingtheMachinebyHand
Theby-passvalvesallowthemachinetobepushedby handwithouttheenginerunning.
Important:Alwayspushthemachinebyhand. Nevertowthemachinebecausehydraulicdamage mayoccur.
DrivingBackward
1.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
2.Slowlypullthemotioncontrolleversrearward
Figure24).
(
Figure24
ToPushtheMachine
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Lowerthemowerdecktothelowestheight-of-cut (HOC).Thiswillallowaccesstothebypassvalves.
3.Opentheby-passvalveonbothpumpsbyturning themcounterclockwise1to2turns.Thisallows hydraulicuidtoby-passthepumpsandthewheels toturn(
Note:Rotatetheby-passvalvesamaximumof2 turnssothevalvedoesnotcomeoutofthebody causinguidtorunout.
Figure25).
StoppingtheMachine
Tostopthemachine,movethemotioncontrolleversto neutral,movetherightsidemotioncontrolleverinto theneutrallockposition,disengagethepowertakeoff (PTO),andturntheignitionkeytooff.
24
5.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.
6.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(
Figure26).
Figure25
1.Pumpby-passvalve
4.Releasetheparkingbrake.
5.Pushthemachinetothedesiredlocation.
6.Settheparkingbrake.
7.Closetheby-passvalves,butdonotovertighten them.Torqueto110to130in-lb(12to15N-m).
Important:Donotstartoroperatethemachine withtheby-passvalvesopen.Damageto systemmayoccur.
TransportingMachines
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby law .Pleasecarefullyreadallthesafetyinstructions. Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.
Totransportthemachine:
1.Raisetheplatformofthemachinebeforedrivingup ontothetrailerortruck.
2.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
3.Ifapplicable,connectthetrailerbrakes.
4.Loadthemachineontothetrailerortruck.
Figure26
1.Tractionunittiedownloop
LoadingMachines
Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure27). Theplatformwhendownandlockedintoposition, extendsbackbetweentherearwheelsandservesasa stopfortippingbackward.Havingafullwidthramp providesasurfacefortheplatformtocontactifthe unitstartstotipbackward.Withtheplatformup,afull widthrampprovidesasurfacetowalkonbehindthe unit.Theoperatorshoulddetermineifitisbesttohave theplatformupordownwhenloading,dependingon conditions.Ifitisnotpossibletouseonefullwidth ramp,useenoughindividualrampstosimulateafull widthcontinuousramp.
Therampshouldbelongenoughsothattheangles donotexceed20degrees( maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.
Figure27).Asteeperangle
25
Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.
SideDischargingorMulching theGrass
Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.
WARNING
Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.
Useextremecautionwhenoperatingauniton aramp.
Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.
Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.
Donotexceeda15degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.
Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.
Thismowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
DANGER
Withoutthegrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.
Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
Neverputyourhandsorfeetunderthemower.
Nevertrytocleardischargeareaormower bladesunlessyoureleasethebailandthepower takeoff(PTO)isoff.Rotatetheignitionkeyto Off.Alsoremovethekeyandpullthewire(s) offthesparkplug(s).
Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.
Figure27
1.Trailer3.Notgreaterthan 15degrees
2.Fullwidthramp4.Fullwidthramp—sideview
AdjustingtheHeight-of-Cut
Theheight-of-cutcanbeadjustedfrom1to5inches (25to127mm)in1/4inch(6mm)increments.
1.Movetheheight-of-cutlevertothetransport position(allthewayup).
2.Toadjust,rotatethepin90degreesandremovethe pinfromtheheight-of-cutbracket
3.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(
4.Pushthebuttonontopandlowertheheight-of-cut levertothepin(
Figure28).
Figure28).
26
g012676
1 2
PositioningtheFlowBafe
G012677
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition(seeFigure30).The suggesteduseforthispositionisafollows.
Figure28
1.Height-of-cutholes3.Height-of-cutlever
2.Height-of-cutpin
AdjustingtheFlowBafe
Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlockand bafetogivethebestqualityofcut.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthebafe,loosenthenut(
4.Adjustthebafeandnutintheslottothedesired dischargeowandtightenthenut.
Figure29).
Useforshort,lightgrassmowingconditions.
Useindryconditions.
Forsmallergrassclippings.
Propelsgrassclippingsfartherawayfromthe mower.
Figure30
PositionB
Usethispositionwhenbagging(Figure31).
Figure29
1.Slot
2.Nut
27
G012678
Figure31
G012679
PositionC
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure32).
Useintall,densegrassmowingconditions.
Useinwetconditions.
Lowerstheenginepowerconsumption.
Allowsincreasedgroundspeedinheavyconditions.
Note:ContactanAuthorizedServiceDealertoorder aW eightKit.
WARNING
Excessiveweightchangescaneffecthandlingand operationofthemachine.Thiscouldcauseserious injurytoyouorbystanders.
Makeweightchangesinsmallincrementsonly.
Evaluatethemoweraftereachweightchangeto ensurethemachinecanbeoperatedsafely.
Figure32
UsingCounterweights
Weightsareinstalledtoimprovehandling,balance andimproveperformance.Weightscanbeaddedor removedtocreateoptimizedperformanceunder differentmowingconditionsandforoperator preference.
Itisrecommendedthatweightsbeaddedor removedoneatatimeuntilthedesiredhandingand balanceisachieved.
28
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Beforeeachuseordaily
Every25hours
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthehydraulicuidlevel.
•Changethehydrauliclter.
•Checkthesafetyinterlocksystem.
•Checktheengineoillevel.
•Cleantheairintakescreen.
•Checkthebrakes.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanfoamaircleanerelement.
•Greasethemowerdeckidlerarms(moreoftenindirtyordustyconditions).
•Greasetheliftlinkage(moreoftenindirtyordustyconditions).
•Lubricatethespeedcontrolslidingparts(moreoftenindirtyordustyconditions).
•Cleanthepaperaircleanerelement.
•Checkthetirepressure.
•Checkthehydraulicuidlevel.
•Changetheengineoil.(moreoftenindirtyordustyconditions)
•Check,cleanandregapthesparkplug.
•Checkthebattery .
•Checkandcleanenginecoolingnsandshrouds.
•Checkthepumpdrivebelt.
•Checkthemowerdeckbelt(s).
•Checkthehydraulichoses.
Every200hours
Every250hours
Every500hours
Beforestorage
Yearly
Important:Refertoyour
•Replacethepaperaircleanerelement.
•Changetheengineoillter.
•ChangethehydraulicoilwhenusingMobil®1oil.
•Adjustthecasterpivotbearing.
•Checktheelectricclutch.
•ChangethehydraulicoilwhenusingT oro®HYPR-OIL™500hydraulicoil.
•Changethehydrauliclter.
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Lubricatethecasterwheelhubs.
•Replacethefuellter.
Engine Operator's Man ual
foradditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.
29
Premaintenance Procedures
RaisingtheMowerforAccess
Thefrontofthemowercanberaisedandsupportedon itsbackforaccessunderthemachineformaintenance.
1.Raisetheplatform.RefertoOperatingthePlatform inOperation.
2.Removethebattery.
Figure34
Figure33
1.Wingnut4.Positivebatterycable
2.Batterycover5.Battery
3.Negativebatterycable
3.Drainthefuelfromthefueltank.RefertoDraining theFuelTankinMaintenance.
4.Removethecapofthehydraulictankandplace apieceofplasticovertheopeningandinstallthe hydrauliccap.Thiswillsealthehydraulictankand preventitfromleakingout.
1.Cap
2.Pieceofplastic
5.Withtwopeople,raisethefrontofthemowersoit restsonthedrivetiresandtheplatformintheup position.
6.Performanymaintenanceonthemachine.
7.Withtwopeople,lowerthefrontofthemowerto theground.
8.Removetheplasticunderthehydraulictankcap.
9.Installthebatteryforthemachine.
3.Hydraulictank
30
Figure35
g012572
1
2
3
4
Figure36
1.Removebattery
2.Withtwopeople,liftthe frontendofthemower (ensuretheplatformisup)
ReleasetheCushionforRear Access
Thecushioncanbereleasedforrearaccesstothe machineformaintenanceoradjustment.
1.Lowertheplatform.
2.Removethehairpincotterpinsoneachsideofthe cushion.
3.Slidethelargewasherswithplasticbushingstothe inside.
4.Removethecushionandlowerittotheplatform.
5.Performanymaintenanceoradjustmentonthe machine.
6.Raisethecushionandslideitontothepinsonboth sidesofthemachine(
Figure36).
7.Slidethelargewasherswithplasticbushingsinto thecushionbracketandsecurethemwithahairpin cotterpin(Figure36).
31
Lubrication
GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.
Lubricatethespeed/tractioncontrollinkagewithadry lubricant,PTFE(Polytetrauoroethylene)(
HowtoGrease
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.
5.Wipeupanyexcessgrease.
Figure40).
Figure38
102cmMowerDeck
LubricatingtheMachine
ServiceInterval:Every50hours—Greasethemower
deckidlerarms(moreoftenindirty ordustyconditions).
Every50hours—Greasethelift linkage(moreoftenindirtyordusty conditions).
Every50hours/Yearly(whichever comesrst)—Lubricatethespeed controlslidingparts(moreoftenin dirtyordustyconditions).
Usethefollowinggraphicsforlocatingthegreasepoints.
Figure39
Lubricatethespeed/tractioncontrollinkagewithadry PTFE(Polytetrauoroethylene)lubricant.
Important:UseonlyadryPTFE (Polytetrauoroethylene)lubricant.Donot useawetoillm,whichwillattractdustanddirt.
Figure37
91cmMowerDeck
32
Figure41
Figure40
GreasingtheFrontCaster Pivots
ServiceInterval:Yearly—Greasethefrontcaster
pivots(moreoftenindirtyordusty conditions).
Lubricatethefrontcasterpivotsonceayear.
1.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance Section.
2.Removethehexplug.Threadagreasezerkintothe hole.
3.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.
4.Removethegreasezerkinthehole.Installthehex plugandcap.
LubricatetheCasterWheel Hubs
1.Sealguard2.Spacernutwithwrench ats
2.Removethecasterwheelfromthecasterforks.
3.Removethesealguardsfromthewheelhub.
4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthespacer nutstotheaxle.Removetheaxle(withtheother spacernutstillassembledtoit)fromthewheel assembly.
5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.
6.Packthebearingswithageneral-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note:Thesealsmustbereplaced.
8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking adhesivetoonespacernutandthreadontotheaxle withthewrenchatsfacingoutward.DoNotthread spacernutallofthewayontotheendoftheaxle. Leaveapproximately1/8inch(3mm)fromtheouter surfaceofthespacernuttotheendoftheaxleinside thenut.
9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.
10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
11.Insertthesecondbearingandnewsealintothe wheel.
ServiceInterval:Yearly—Lubricatethecasterwheel
hubs.
1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.
12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.
33
13.Torquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Makesure axledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully .
EngineMaintenance
ServicingtheAirCleaner
ServiceInterval/Specication
Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthecaster tire.Thetireshouldnotspinfreely(morethan1or 2revolutions)orhaveanysideplay .Ifthewheel spinsfreely,adjusttorqueonspacernutuntilthere isaslightamountofdrag.Reapplythreadlocking adhesive.
Inspectthefoamandpaperelementsandreplacethem iftheyaredamagedorexcessivelydirty.
Note:Servicetheaircleanermorefrequently(every fewoperatinghours)iftheoperatingconditionsare extremelydustyorsandy .
Important:Donotoilthefoamorpaperelement.
RemovingtheFoamandPaper Elements
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage
Figure42).
(
4.Unscrewthecoverknobsandremovetheaircleaner cover(Figure42).
5.Unscrewthehoseclampandremovetheaircleaner assembly(
6.Carefullypullthefoamelementoffthepaper element(Figure42).
1.Cover
2.Hoseclamp4.Foamelement
Figure42).
Figure42
3.Paperelement
34
CleaningtheFoamAirCleanerElement
ServiceInterval:Every25hours
1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifitis tornorworn.
ServicingthePaperAirCleaner Element
ServiceInterval:Every50hours—Cleanthepaperair
cleanerelement.
Every200hours—Replacethepaper aircleanerelement.
1.Cleanthepaperelementbytappinggentlytoremove dust.Ifitisverydirty,replacethepaperelement withanewone(
2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.
Figure42).
Note:Therearedifferentoilcapacitiesforthedifferent modelslistedinthismanual.Ensurethecorrectamount ofoilisused.
Important:Remembertoadd80%oftheoiland thengraduallyllittothefullmarkonthedipstick.
OilType:Detergentoil(APIserviceSF,SG,SH,SJ
orSL)
EngineOilCapacity:58ounces(1.7liter)withthe lterremoved;51ounces(1.5liter)withoutthelter removed
Viscosity:Refertothetablebelow
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaperElements
Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.
1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure42).
2.Placetheaircleanerassemblyontotheaircleaner baseorhoseandsecureit(Figure42).
3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure42).
ServicingtheEngineOil
ServiceInterval:Beforeeachuseordaily—Checkthe
engineoillevel.
Aftertherst8hours—Changethe engineoil.
Every100hours—Changetheengine oil.(moreoftenindirtyordusty conditions)
Every200hours—Changetheengine oillter.
Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.
Figure43
CheckingtheEngineOilLevel
Note:Checktheoilwhentheengineiscold.
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.
Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position(
Figure44).
35
G008792
1
2
5
6
7
3
9
10
4
8
3.Stoptheengine,removethekey ,andwaitforall
g012596
2
3
4
1
movingpartstostopbeforeleavingtheoperating position(Figure45).
Figure44
ChangingtheEngineOil
Note:Disposeoftheusedoilatarecyclingcenter.
1.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
Figure45
4.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure46).
36
G008796
2
3
4
5
6
1
G012845
3/4
2
3
4
5
6
1
Figure46
ChangingtheEngineOilFilter
Note:Changetheengineoilltermorefrequently
whenoperatingconditionsareextremelydustyorsandy.
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Placearagundertheoilltertosoakupanyspilled oil.
Important:Spilledoilmaydrainunderthe engineandontotheclutch.Oilspilledonthe clutchmaydamagetheclutch,causetheblades tostopslowlywhentheclutchisswitchedoff andcausetheclutchtoslipwhentheclutchis switchedon.Wipeupanyspilledoil.
3.Changetheengineoillter(
Figure47).
Figure47
Note:Ensuretheoilltergaskettouchestheengine
andthenanextra3/4turniscompleted.
4.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.
ServicingtheSparkPlug
ServiceInterval:Every100hours
Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.
TypeforallEngines:NGK
AirGap:0.030inch(0.75mm)
37
®
BPR4ESorequivalent
RemovingtheSparkPlug
G008794
1
2
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
Figure50
Figure48
CheckingtheSparkPlug
Important:Nevercleanthesparkplug(s).Always
replacethesparkplug(s)whenithas:ablack coating,wornelectrodes,anoilylm,orcracks.
Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.
Setthegapto0.030inches(0.75mm).
Figure49
InstallingtheSparkPlug
Tightenthesparkplug(s)to16ft.-lb(22N-m).
38
FuelSystem
ServicingtheFuelFilter
Maintenance
DrainingtheFuelTank
Note:Thereisnootherrecommendedwaytodrain
fuelfromthetank,otherthanusingasyphonpump.A syphonpumpcanbepurchasedatahardwarestore.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
Draingasolinefromthefueltankwhenthe engineiscold.Dothisoutdoorsinanopenarea. Wipeupanygasolinethatspills.
Neversmokewhendraininggasoline,andstay awayfromanopenameorwhereasparkmay ignitethegasolinefumes.
1.Parkthemachineonalevelsurface.Disengagethe powertakeoff(PTO),settheparkingbrake,turnthe ignitionkeytoOffandremovethekey .
2.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(
3.Removethefuelcap.
4.Insertasyphonpumpintothefueltank.
5.Usingthesyphonpump,drainthefuelintoaclean gascan(
6.Wipeupanyspilledfuel.
Figure51).
Figure52).
ReplacingtheFuelFilter
ServiceInterval:Yearly
Neverinstalladirtylterifitisremovedfromthefuel line.
Note:Notehowthefuellterisinstalledinorderto installthenewltercorrectly.
Note:Wipeupanyspilledfuel.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Closefuelshut-offvalve.
4.Squeezetheendsofthehoseclampstogetherand slidethemawayfromthelter(
Figure52
Figure52).
1.Fuelcap
Figure51
1.Fuellter
2.Hoseclamp
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclampsclose tothelter.
7.Openthefuelshut-offvalve.
8.Checkforfuelleaksandrepairifneeded.
9.Wipeupanyspilledfuel.
39
3.Fuelline
ElectricalSystem Maintenance
ServicingtheBattery
ServiceInterval:Every100hours
Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatterycase.Ifthebattery terminalsarecorroded,cleanthemwithasolutionof fourpartswaterandonepartbakingsoda.Applyalight coatingofgreasetothebatteryterminalstoprevent corrosion.
Voltage:12V
WARNING
WARNING
Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.
AlwaysDisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.
AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative(black) cable.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling .
DANGER
Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.
3.Disconnectthenegativebatterycablefromthe negative(-)batteryterminal(
4.Slidetheredterminalbootoffthepositive(red) batteryterminal.Thenremovethepositive(red) batterycable(Figure53).
5.Removethebatteryholddownplate( removethebattery.
Figure53).
Figure53)and
InstallingtheBattery
1.Placethebatteryontothemachine(Figure53).
2.Securethebatterywiththeholddownplate,j-bolts, andlocknuts.
3.First,installthepositive(red)batterycableto positive(+)batteryterminalwithanut,washerand
Figure53).Slidetherubbercoveroverthepost.
bolt(
4.Theninstallthenegativebatterycableandground wiretothenegative(-)batteryterminalwithanut, washerandbolt(Figure53).
Note:Thebatterycableswillcrossovereachother whenthearecorrectlyinstalled(
Figure53).
Whenremovingorinstallingthebattery ,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
40
g013199
1
2 3 4
5
6
Note:Donotrunthemachinewiththebattery
g013015
disconnected,electricaldamagemayoccur.
Figure54
Figure53
1.Wingnut4.Positivebatterycable
2.Batterycover5.Battery
3.Negativebatterycable6.Thebatterycablescross wheninstalledcorrectly
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthatcan explode.
1.PositiveBatteryPost
2.NegativeBatteryPost
3.Red(+)ChargerLead
4.Black(-)ChargerLead
ServicingtheFuses
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance.Ifafuseblows,checkthecomponent orcircuitforamalfunctionorshort.
1.Releasetheoperatorcushionfromtherearofthe machine.
2.Pulloutonthefusetoremoveandreplaceit
Figure55).
(
3.Installtheoperatorcushion.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).
1.Removethebatteryfromthechassis;referto RemovingtheBattery.
2.Chargebatteryfor1hourat25to30ampsor6 hoursat4to6amps.
1.Controls
2.Wire
Figure55
3.Fuses
3.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(
Figure54).
4.Installthebatteryontothemachineandconnectthe batterycables,refertoInstallingtheBattery.
41
DriveSystem
g015241
g015369
1 2
Maintenance
AdjustingtheTracking
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1.Pushbothcontrolleversforwardthesamedistance.
2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.
3.Releasethecushionfromtherearofthemachine.
4.Rotatetherightcableadjustmenttopositionthe rightmotioncontrolinthecenterofthecontrol panelneutrallockslot(
Figure57).
Figure57
Figure56
1.Leftmotioncontrollever
2.Rightmotioncontrollever4.Alignthecontrollevers
3.Neutrallockedposition
fronttoback
5.Rotatetheleftcableadjustmenttomatchtheleft wheelspeedtothepreviouslysetrightwheelspeed. Adjustinquarter-turnincrementsuntilthemachine tracksstraight.
Note:Onlyadjusttheleftcabletomatchtheleft wheelspeedtotherightwheelspeed.Donotadjust therightwheelspeedasthiswillpositiontheright motioncontrolleveroutofthecenterforthecontrol panelneutrallockslot.
1.Leftcableadjustment
2.Rightcableadjustment
6.Checkforpropertracking.
Note:Ifthemachinewillnotstartafteradjusting thetracking,makesureproximityswitchtargetaligns withboltattachedtomotioncontrollever.Referto AdjustingtheProximitySwitch(page42).
7.Repeatthecableadjustmentuntilthetrackingis correct.
8.Checkthatthemachinedoesnotcreepfromneutral withtheparkbrakesdisengaged.
Important:DoNotrotatethelinkagetoofar,as thismaycausethemachinetocreepinneutral.
AdjustingtheProximitySwitch
Usethisprocedureifthemachinewillnotstartafter adjustingthetracking.
1.Checkandensuretheboltattachedtothemotion controlleveralignswiththeproximityswitchtarget (Figure58).
2.Ifneeded,loosentheboltsandadjusttheproximity switchuntilthetargetalignswithboltattachedtothe motioncontrollever(
Figure58).
3.Checkthedistanceofthebolttotheproximity switch.Itneedstobebetween0.050and0.090 inches(1.27to2.29mm)(Figure58).
42
4.Ifadjustmentisneeded,loosenthejamnutand
G015609
1 6
2 3 4
4
2
5
6
adjustthebolttothecorrectdistance.Tightenthe jamnutafteradjustingthebolt(Figure58).
5.Testthesafetyinterlocksystembeforeoperation.
Figure59
AdjustingtheCasterPivot Bearing
ServiceInterval:Every500hours/Yearly(whichever
comesrst)
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
Figure58
1.Proximityswitchtarget4.Boltattachedtothemotion controllever
2.Proximityswitch5.Distancebetween0.050 and0.090inches(1.27to
2.29mm)isneeded
3.Boltsandnuts6.Jamnut
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethedustcapfromcasterandtightenlock
Figure60).
nut(
4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(
Figure60).
Important:Makesurespringwashersare installedcorrectlyasshowninFigure60.
5.Installthedustcap(
Figure60).
Maintaintheairpressureinthereartiresat12-14psi (83-97kPa).Uneventirepressurecancauseanuneven cut.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
43
Figure60
1.SpringWashers3.DustCap
2.LockNut
AdjustingtheElectricClutch
ServiceInterval:Every500hours—Checktheelectric
clutch.
Theclutchisadjustabletoensureproperengagement andproperbraking.
1.Inserta0.015–0.021inch(0.381–0.533mm)feeler gaugethroughoneinspectionslotinthesideofthe assembly.Makesureitisbetweenthearmatureand therotorfrictionsurfaces.
Figure61
1.Adjustingnut3.Feelergauge
2.Slot
Thegapneedstobeatleast.015inches(0.381mm) andnotmorethan.021inches(0.533mm).
2.Ifadjustmentisneeded,thensetat.015inches(0.381 mm)foreachofthethreeadjustmentslotpositions. Tightenthelocknutsuntilthereisslightbindingon thefeelergaugebutitcanbemovedeasilywithinthe airgap(
Figure61).
3.Repeatthisfortheremainingslots.
4.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.
44
CoolingSystem
g017626
1
2
3
4
5
Maintenance
CleaningtheAirIntakeScreen
ServiceInterval:Beforeeachuseordaily
Beforeeachuseremoveanybuild-upofgrass,dirt orotherdebrisfromthecylinderandcylinderhead coolingns,airintakescreenonywheelend,and carburetor-governorleversandlinkage.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine.
CleaningtheCoolingSystem
ServiceInterval:Every100hours—Checkandclean
enginecoolingnsandshrouds.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removetheairintakescreenandfanhousing
Figure62).
(
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installtheairintakescreenandfanhousing
Figure62).
(
1.Guard
2.Engineairintakescreen
3.Bolt
Figure62
4.Fanhousing
5.Screw
45
BrakeMaintenance
g013291
4
ServicingtheBrake
Beforeeachuse,checkbrakesonbothalevelsurface andslope.
Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.
CheckingtheParkingBrake
ServiceInterval:Beforeeachuseordaily
Important:Ensurethemowerisonalevelsurface whencheckingandadjustingthebrake.
1.Parkthemachineonalevelsurface,disengagethe PTO.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
4.Withthebrakereleased,measurethedistance betweenthebrakebarandthetire.Thedistance needsbebetween3/16and5/16inches(5and8
Figure63).RefertoAdjustingtheParking
mm)( Brakewhenadjustmentisneeded.
AdjustingtheBrakes
Ifthegapbetweenthebrakebarandtireisnotcorrect, anadjustmentisrequired.
1.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
4.Toadjustthebrake,removeclevispinandhairpin cotterpinfromthelowerbrakeleverandyoke
Figure64).
(
5.Adjusttheyoke.Thedistancebetweenthebrake barandthetireneedsbebetween3/16and5/16 inches(5and8mm).T otightenthebrake,rotatethe yokeup.Toloosenthebrake,rotatetheyokedown
Figure63).
(
6.Checkthebrakeoperationagain;refertoChecking theParkingBrake.
7.Securetheyoketolowerbrakeleverwiththeclevis pinandhairpincotterpin(
Figure64).
Figure64
Figure63
1.Tire
2.Brakebar
3.Gapbetween3/16and 5/16inches(5and8mm)
1.Yoke3.Lowerbrakelever
2.Clevispin
46
4.Hairpincotterpin
BeltMaintenance
CheckingtheBelts
ServiceInterval:Every100hours—Checkthepump
drivebelt.
Every100hours—Checkthemower deckbelt(s).
Checkbeltsforcracks,frayededges,burnmarks,wear, signsofoverheatingoranyotherdamage.
Thesignsofawornmowerbeltaresquealingwhilethe beltisrotating,bladesslippingwhileyouarecutting grass,frayedbeltedges,burnmarks,andcracks.Replace themowerbeltifyoudetectanyofthesesigns.
ReplacingtheMowerDeck Beltfor91cmMowers
Important:Thefastenersonthecoversofthis
machinearedesignedtoremainonthecoverafter removal.Loosenallofthefastenersoneachcovera fewturnssothatthecoverisloosebutstillattached, thengobackandloosenthemuntilthecover comesfree.Thiswillpreventyoufromaccidentally strippingtheboltsfreeoftheretainers.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosentheboltsandremovetherightbeltcover withtheboltattachedtoit.
4.Removethespringfromtheanchorpostontheidler pulleyarm(
5.Removethewornmowerbelt(Figure65).
6.Installthenewmowerbeltaroundtheclutchpulley, deckpulleysandidlerpulley(
7.Installthespringontotheanchorpostontheidler pulleyarm(
8.Installthebeltcoverontothecuttingunitandsecure thebolt.
Figure65).
Figure65).
Figure65).
Figure65
1.Belt
2.Springloadedidlerpulley
3.Spring
ReplacingtheMowerDeck Beltsfor102cmMowers
Important:Thefastenersonthecoversofthis
machinearedesignedtoremainonthecoverafter removal.Loosenallofthefastenersoneachcovera fewturnssothatthecoverisloosebutstillattached, thengobackandloosenthemuntilthecover comesfree.Thiswillpreventyoufromaccidentally strippingtheboltsfreeoftheretainers.
ReplacingtheRightMower DeckBelt
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosentheboltsandremovethebeltcoverswiththe boltsattachedtothem.
4.Removethespringfromtheanchorpostontheidler pulleyarm(
5.Removethewornmowerbelt(Figure65).
6.Installthenewmowerbeltaroundthedeckpulleys andidlerpulley(Figure65).
7.Installthespringontotheanchorpostontheidler pulleyarm(Figure65).
8.Installthebeltcoversontothecuttingunitand securethebolts.
Figure65).
47
Figure66
1.Belt
2.Spring
3.Springloadedidlerpulley
1.Belt
2.Springloadedidlerpulley
Figure67
3.Spring
ReplacingtheLeftMowerDeck Belt
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosentheboltsandremovethebeltcoverswiththe boltsattachedtothem.
4.Toremovetheleftmowerbelt,therightmowerbelt needstoberemovedrst.RefertoReplacingthe RightMowerBelt.
5.Removethespringfromtheanchorpostontheidler pulleyarm(
6.Removethewornmowerbelt(
7.Installthenewmowerbeltaroundthedeckpulleys, clutchpulleyandidlerpulley(Figure65).
8.Installthespringontotheanchorpost(
9.Installtherightmowerbelt.RefertoReplacingthe RightMowerBelt.
Figure65).
Figure65).
Figure65).
ReplacingthePumpDriveBelt
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethemowerdeckbeltfromtheclutchon 30inmowerdecksorremovetheleftmowerbelt fromtheclutchfor40inmowerdecks.Referto ReplacingtheMowerDeckBelts.
4.Tiltthemachineonit'sback.Referto Pre-Maintenanceatthebeginningofthe MaintenanceSection.
5.Unhooktheidlerspringfromtheframe(
6.Installthenewbeltaroundenginepumpdrivepulley andthetwopumppulleys.
7.Installtheidlerspringtotheframe(
Figure68).
Figure68).
10.Installthebeltcoversontothecuttingunitand securethebolts.
48
Figure68
1.Hydraulicpumps
2.Idlerpulley5.Pumpdrivebelt
3.Clutchpulley
4.Clutchretainer
6.Pumpdrivepulley
ControlsSystem Maintenance
AdjustingtheMotionControl HandlePositions
AdjustingtheRightSideMotionControl Lever
Ifthemotioncontrolleversdonotalignhorizontally, adjusttherightsidemotioncontrollever.
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
1.DisengagethePTO,movetherightsidemotion controllevertotheneutralpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
8.Lowerthemachinetotheoperatingposition. RefertoPreMaintenanceatthebeginningofthe MaintenanceSection.
9.Installthemowerdeckbelttotheclutchon30in mowerdecksorinstalltheleftmowerbeltinstallthe clutchfor40inmowerdecks.RefertoReplacingthe MowerDeckBelts.
3.Pushtherightmotioncontrolleverdownoutof lockedneutralposition(
Figure69).
4.Checkifitalignshorizontallywiththeleftmotion controllever(
1.Leftmotioncontrollever3.Checkthehorizontal
2.Rightmotioncontrollever inneutrallockedposition
Figure69).
Figure69
alignmenthere
4.Rightmotioncontrollever
5.Toadjusttherightmotioncontrolleverhorizontally, thecamneedstobeadjusted.
6.Removethecushionfromtherearofthemachine.
7.Loosenthenutholdingthecam(Figure70).
8.Adjustthecamuntiltherightmotioncontrollever alignswiththeleftmotioncontrolleverandtighten thenutandboltforthecam.
49
G012704
1 2
3
Figure70
G012705
1 2
2
3
1.Switchscrews
2.Cam
3.Nut
9.Afterthecamisadjusted,theleverswitchneedsto bechecked.
10.Checkthegapbetweenthecontrolleverandswitch asshownin inch(3mm)withtherightmotioncontrolleverin theneutral,unlockedposition.
11.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch(Figure70andFigure71).
Figure71.Thegapneedstobean1/8
1.Switch(onfrontside)
2.1/8inch(3mm)
12.Tightentheswitchscrews.
Figure71
3.Rightmotioncontrollever intheneutralunlocked position
AdjustingtheNeutralPositionforthe MotionControlLevers
Important:Ensurethetrackingofthemoweris
correctafteradjustingthemotioncontrollevers. Adjustingthetrackingandaligningthemotion controlleversfronttobackisthesameprocedure
Figure72).
(
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
Ifthemotioncontrolleversdonotalignfronttoback, ortherightsidecontrolleverdoesnotmoveeasilyinto theneutrallockposition,adjustmentisrequired.
1.Afterthehorizontalalignmentisnished,check thefronttobackalignmentbyslightlypushingthe controlleversforwardtotakeupanyslackinthe
50
linkageforthecontrollevers(
Figure72).
G012706
1
2
3
4
Figure72
1.Leftmotioncontrollever
2.Rightmotioncontrollever4.Alignthecontrollevers
3.Neutrallockedposition
fronttoback
2.Ensuretherightmotioncontrollevermoveseasily intotheneutrallockposition.
Note:Turnthecableadjustmentclockwisetomove themotioncontrolhandleforward.Turnthecable adjustmentcounter-clockwisetomovethemotion controlhandlerearward.
3.Rotatethecableadjustmentonrightsidewhen adjustmentisneeded.Adjustthecableadjustmentin quarter-turnincrements.
4.Aftertherightmotioncontrollevermoveseasily intotheneutrallockposition,adjusttheleftmotion controllevertoalignwiththerightmotioncontrol lever.
5.Checkforpropertracking.RefertoAdjustingthe TrackingintheMaintenanceSection.
Figure73
1.Leftcableadjustment3.Platformdown
2.Rightcableadjustment
51
HydraulicSystem
g012685
1
2
3
4
Maintenance
ServicingtheHydraulic System
HydraulicOilType:Toro hydraulicoilorMobil
®
®
HYPR-OIL
115W-50syntheticmotoroil.
Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.
HydraulicSystemOilCapacity:67oz.(2.0l)
CheckingtheHydraulicFluid
ServiceInterval:Aftertherst8hours
Every50hours
HydraulicOilType:Toro hydraulicoilorMobil
®
Important:Useoilspeciedorequivalent.Other uidscouldcausesystemdamage.
HydraulicSystemOilCapacity:67oz.(2.0l)
Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoilis cold.Thebafeinsidethetankhastwolevelsdepending iftheoiliswarmorcold.
1.Positionmachineonalevelsurface.
2.Disengagethepowertakeoff(PTO)andshutoff theengine.
3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.
4.Cleanareaaroundcapandllerneckofhydraulic
Figure74).
tank(
®
HYPR-OIL
115W-50syntheticmotoroil.
500
500
5.Removecapfromllerneck.Lookinsidetocheck theuidlevelinthereservoir.(Figure74).
6.Adduidtothereservoiruntilitreachesthecold levelofthebafe.
7.Runthemachineatlowidlefor15minutestoallow anyairtopurgeoutofthesystemandwarmuid. RefertoStartingandStoppingtheEngine.
8.Rechecktheuidlevelwhiletheuidiswarm.If required,adduidtothereservoiruntilitreaches thehotlevelofthebafe.
Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidiswarm(Figure74).
9.Installcaponllerneck.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
Usecardboardorpapertondhydraulic leaks.
Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
1.Cap3.Colduidlevel-full
2.Bafe4.Hotuidlevel-full
Figure74
ReplacingtheHydraulicFluid
ServiceInterval:Every250hours—Changethe
hydraulicoilwhenusingMobil Every500hours—Changethe
hydraulicoilwhenusingT oro HYPR-OIL
500hydraulicoil.
WARNING
Hothydraulicuidcancausesevereburns.
Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
52
®
1oil.
®
3.Removehydraulicreservoircap.
ReplacingtheHydraulicFilter
4.Locatethefronthydraulichoseunderthehydraulic tankandplacedrainpanunderthetank(
Figure75).
5.Loosenthehoseclampandmoveitdownthehose.
6.Removethefronthydraulichoseandallowtheuid torunoutofthetank.
Figure75
1.Hydraulictank3.Fronthydraulichose
2.Hydrauliclter
ServiceInterval:Aftertherst8hours
Every500hours/Y early(whichever comesrst)
WARNING
Hothydraulicuidcancausesevereburns.
Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
Important:Donotsubstituteautomotiveoil lterorseverehydraulicsystemdamagemay result.
3.Locatethelterandplacedrainpanunderlter
Figure76).
(
7.Changethehydrauliclter.RefertoReplacingthe HydraulicFilter.
8.Connectthehydraulichoseunderthetank.
9.Adduidtothetankuntilitreachesthecoldbafe ofthetank.
Important:Useoilspeciedorequivalent. Otheruidscouldcausesystemdamage.
10.Installthehydraulictankcap.
11.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.
12.Checktheleveloftheuidandadduid,ifrequired.
Donotoverll.
Figure76
1.Hydraulictank
2.Hydrauliclter
4.Removetheoldlterandwipethelteradapter gasketsurfaceclean(Figure77).
5.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.
6.Installreplacementhydrauliclterontothelter adapter.Turntheoillterclockwiseuntiltherubber gasketcontactsthelteradapter,thentightenthe lteranadditional1/2turn(Figure77).
53
CheckingtheHydraulicLines
ServiceInterval:Every100hours
Checkhydraulichosesandhosesforleaks,loosettings, kinkedhoses,loosemountingsupports,wear,weather andchemicaldeterioration.Makenecessaryrepairs beforeoperating.
Note:Keepareasaroundhydraulicsystemcleanfrom grassanddebrisbuildup.
Figure77
1.Hydrauliclter
2.Gasket
3.Adapter
7.Cleanupanyspilleduid.
8.Checktheuidinthereservoir,adduidtothetank untilitreachesthecoldbafeofthetank.
Important:Useoilspeciedorequivalent. Otheruidscouldcausesystemdamage.
9.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkforleaks.Ifoneorbothwheelswillnotdrive, refertoBleedingHydraulicSystem.
10.Rechecklevelandadduid,ifrequired.Donot
overll.
BleedingtheHydraulicSystem
Thetractionsystemisselfbleeding,however,itmaybe necessarytobleedthesystemifuidischangedorafter workisperformedonthesystem.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafewhours byadoctorfamiliarwiththistypeofinjury. Gangrenemayresultifthisisnotdone.
Keepbodyandhandsawayfrompinholeleaks ornozzlesthatejecthighpressurehydraulic uid.
Usecardboardorpapertondhydraulicleaks.
Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.
Makesureallhydraulicuidhosesandhosesare ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto hydraulicsystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsofftheground.
4.Starttheengineandmovethethrottlecontroltoidle position.
Ifthedrivewheeldoesnotrotate,itispossibleto assistthepurgingofthesystembycarefullyrotating thetireintheforwarddirection.
5.Checkthehydraulicuidlevelasitdropsadduid asrequiredtomaintaintheproperlevel.
6.Repeatthisprocedurefortheoppositewheel.
7.Thoroughlycleantheareaaroundeachofthecharge pumphousings.
54
MowerDeck Maintenance
ServicingtheCuttingBlades
Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
WARNING
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator's orbystander'sarea,resultinginseriouspersonal injuryordeath.
Inspectthebladesperiodicallyforwearor damage.
Replaceawornordamagedblade.
BeforeInspectingorServicingthe Blades
CheckingforBentBlades
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromalevelsurfacetothe cuttingedge,positionA,oftheblades( Notethisdimension.
Figure79).
Parkthemachineonalevelsurface,disengagetheblades andsettheparkingbrake.Turntheignitionkeytooff. Removethekeyanddisconnectthesparkplugwires fromthesparkplugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges( arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
2.Inspecttheblades,especiallythecurvedarea.Ifyou noticeanycracks,wear,oraslotforminginthisarea immediatelyinstallanewblades(
Figure78
Figure78).Iftheedges
Figure78).
Figure79
1.Measureherefromblade tohardsurface
4.Rotatetheoppositeendsofthebladesforward.
5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin
3and4mustnotexceed1/8inch(3mm).If
steps thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.
2.PositionA
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
Alwaysreplacebentordamagedbladewith anewblade.
Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
1.CuttingEdge3.Wear/slotForming
2.CurvedArea4.Crack
RemovingtheBlades
Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum performanceandcontinuedsafetyconformanceof
55
themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
1.Holdthebladeendusingaragorthickly-padded glove.
2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(
Figure80).
Figure80
Figure82
1.Blade2.Balancer
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure83).
Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead
Figure83).Torquethebladeboltto85-110ft-lb
( (115-150N-m).
1.SailAreaofBlade3.Curvedwasher
2.Blade4.BladeBolt
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure81).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
Figure81
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure82).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure80).Repeatthis procedureuntilthebladeisbalanced.
Figure83
1.SailAreaofBlade
2.Blade
3.SpringDisk
4.BladeBolt
5.ConeTowardsBoltHead
LevelingtheMower
PreparingtheMachine
1.Positionmoweronaatsurface.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
56
4.Checkthetirepressureofbothdrivetires.Ifneeded,
1
2 3 2
4
g012739
5 6 7 8
adjustto13psi(90kPa)
5.Lowerthemowertothe3inch(76mm)height-of-cut position.
Note:Theactualcuttingheightwillnotbeadjusted untilthedeckhasbeenleveled.RefertoAdjusting HeightofCut.
6.Checkthedistancebetweentheswivels,measureat thecenteroftheswivels(center-to-centerlength) onthethreadedrod.Thislengthneedstobe 19-1/2inches(49.5cm)for91cmmowerdecksand 17-3/16inches(43.7cm)for102cmmowerdecks
Figure84).
(
7.Inspectthefourchains.Thechainsneedtohave tension.
8.Ifeitherrearchainisloose,thelengthofthethreaded rodonthatsidewillneedtobeadjustedtogetequal tensiononbothrearchains.
9.Usethejamnutsatthefrontswiveltoadjustthe lengthbetweenfrontandrearswivelsonthatside
Figure84).
(
10.Ifeitherfrontchainisloose,loosenthenutonthe upperchainboltandthejamnutontheadjustment bolt.
11.Usetheadjustmentbolttogetequaltensiononboth frontchains(
Figure84).
12.Tightenthenutontheupperchainboltandthejam nutontheadjustmentbolt.
Figure84
1.Measurehereatthe centeroftheswivels (center-to-centerlength)
2.Swiveljamnuts
3.Frontswivel7.JamNut
4.Frontchain8.Upperchainbolt
5.Rearchain
6.Adjustmentbolt
AdjustingtheLeftSideFront-to-Rear MowerPitch
1.Positiontheleftbladefront-to-rear
2.MeasuretheleftbladeattheAlocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(Figure85).
3.MeasuretheleftbladeattheBlocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(
Figure85).
4.Themowerbladeshouldbea1/4to3/8inch(6 to10mm)loweratpositionAthanatposition B(Figure85).Ifitisnotcorrect,proceedtothe followingsteps.
5.Loosenthenutontheupperchainboltandthejam nutontheadjustmentbolt(
57
Figure84).
6.Usetheadjustmentbolttoachieve1/4to3/8inch
g012784
A
B
g012787
A
C
(6to10mm)lowerinfrontatAthanintherearat B(Figure84).
7.Tightenthenutontheupperchainboltandthejam nutontheadjustmentbolt.
Figure86
Figure85
1.Measureherefromthe bladetoahardsurface
2.MeasureatAandB
LevelingtheMowerSide-to-Side
1.Positiontheleftbladefront-to-rear(Figure86).
2.MeasuretheleftbladeattheAlocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(
3.Positiontherightbladefront-to-rear(Figure86).
4.MeasuretherightbladeattheClocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(
5.ThemeasurementbetweenlocationAandCneeds tobewithin1/8inch.Ifitisnotcorrect,adjust thefrontchainatlocationCtoachievethecorrect height.
Figure86).
Figure86).
1.Measureherefromblade tohardsurface
2.MeasureatAandC
AdjustingtheRightSideFront-to-Rear MowerPitch
1.Positiontherightbladefront-to-rear(Figure87).
2.MeasuretherightbladeattheClocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(Figure87).
3.MeasuretherightbladeattheDlocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(
4.Themowerbladeshouldbea1/4to3/8inch(6 to10mm)loweratpositionCthanatposition
Figure87).Ifitisnotcorrect,proceedtothe
D( followingsteps.
5.Thelengthofthethreadedrodontherightsidewill needtobeadjustedtoachieveproperfront-to-rear pitch.
6.Usethejamnutsatthefrontswiveltoadjustthe lengthbetweenfrontandrearswivelsonthatside.
7.Checktomakesurethereisequaltensiononallfour chains.Togetequaltensiononallfourchains,make minoradjustmentstomaintainproperdeckpitch.
Figure87).
58
g012788
C
D
Figure87
1.Measureherefromblade tohardsurface
2.MeasureatCandD
AdjustingtheHeightofCut
1.Lowerthemowertothe3inch(76mm)height-of-cut position.
2.Positiontheleftbladefront-to-rear(
3.MeasuretheleftbladeattheAlocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(Figure86).
4.Positiontherightbladefront-to-rear(
5.MeasuretherightbladeattheClocation,froma levelsurfacetothecuttingedgeofthebladetipand recordthismeasurement(Figure86).
6.ThemeasurementbetweenlocationAandCneeds tobewithinan1/8inchofthe3inch(76mm) height-of-cutsetting.Ifitisnotcorrect,proceedto thefollowingsteps.
7.Loosenthejamnutsatbothendsoftheturnbuckle
Figure88).
(
Figure86).
Figure86).
Figure88
1.Jamnut
2.Turnbuckle
3.Grooveindicatinglefthand threads
AdjustingtheCompressionSpring
Note:Adjustingthecompressionspringwillalterhow
muchthedeckwilloatandhowmucheffortittakesto liftthedeckwhenusingtheheight-of-cuthandle.
Morespringcompressionwillreducethehandlelift forcerequiredandcausethedecktooatmore.
Lessspringcompressionwillincreasethehandlelift forcerequiredandcausethedecktooatless.
1.Raisethedeckliftleverandlockintothetransport position.
2.Checkthelengthofthecompressionspring. Nominallengthis11-1/8inches(28.2cm)for91cm mowerdecksand10-1/8inches(25.7cm)for102 cmmowerdecks(
Figure89).
Note:Theendoftheturnbucklewiththegroove machinedinithaslefthandthreads(Figure88).
8.Adjusttheturnbuckletoraiseorlowerthedeck heighttoachieve3inchesatlocationsAandC.
9.Tightenthejamnutsatbothendsoftheturnbuckle.
3.Adjustthisdistance,bylooseningthespringjam nutandturningthenutinfrontofeachspring
Figure89).
(
4.Lockthenutintopositionbytighteningthespring jamnut(
59
Figure89).
1
g012783
4 3 2
g015594
1
6 2
4
7
3
5
Figure90
Figure89
1.10-1/8inch(25.7cm)for 102cmmowerdecksand 11-1/8inch(28.2cm)for 91cmmowerdecks
2.Springjamnut4.Compressionspring
3.Frontnut
ReplacingtheGrassDeector
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator'sor bystander'sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring
5.Springinstalled
7.Jhookendofspring
2.Placethespacerandspringontograssdeector. PlaceoneJendofthespringbehindthedeckedge.
Note:MakesureoneJendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas shownin
Figure90.
3.Installtheboltandnut.PlaceoneJhookendofthe springaroundthegrassdeector(Figure90).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets( Removedamagedorworngrassdeector.
Figure90).
60
Cleaning
Storage
CleaningUndertheMower
ServiceInterval:Beforeeachuseordaily
Removethegrassbuildupunderthemowerdaily.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethefrontofthemachineandusejackstandsto supportthemower.
WasteDisposal
Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.
CleaningandStorage
1.Disengagethepowertakeoff(PTO),settheparking brake,andturntheignitionkeytooff.Removethe key.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engine.Cleandirtandchafffromtheoutsideofthe engine'scylinderheadnsandblowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotpressurewash themachine.Avoidexcessiveuseofwater, especiallynearthedrivesystemandengine. Pressurewashingcanforcedirtandwaterinto criticalparts,suchasspindlebearingsand electricalswitches.
3.Checkthebrake;refertoServicingtheBrakein BrakeMaintenance(page46).
4.Servicetheaircleaner;refertoServicingtheAir CleanerinEngineMaintenance(page34).
5.Greasethemachine;refertoGreasingand LubricationinLubrication(page32).
6.Changetheengineoil;refertoServicingtheEngine inEngineMaintenance(page34).
7.Checkthetirepressure;refertoCheckingtheTire PressureinDriveSystemMaintenance(page42).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelinthe
tank.
B.Runenginetodistributeconditionedfuelthrough
thefuelsystem(5minutes).
C.Stopengine,allowtocoolanddrainthefuel
tank;refertoServicingtheFuelTankin FuelSystemMaintenance(page39),oroperate engineuntilitstops.
D.Restartengineandrununtilitstops.Repeat,on
Chokeuntilenginewillnotrestart.
E.Disposeoffuelproperly.Recycleasperlocal
codes.
Note:Donotstorestabilizer/conditioned gasolineover90days.
9.Removethesparkplug(s)andcheckits condition;refertoServicingtheSparkPlugin EngineMaintenance(page34).Withthespark plug(s)removedfromtheengine,pourtwo tablespoonsofengineoilintothesparkplug hole.Nowusethestartertocranktheengineand
61
distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).
10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.
11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
12.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachineto protectitandkeepitclean.
62
Troubleshooting
Problem
Enginewillnotstart,startshard,orfails tokeeprunning.
Enginelosespower.
PossibleCauseCorrectiveAction
1.Fueltankisemptyorshut-offvalve closed.
2.Chokeisnoton.
3.Sparkplugwireislooseor disconnected.
4.Sparkplugispitted,fouled,orthegap isincorrect.
5.Aircleanerisdirty.
6.Dirtinthefuellter.6.Replacethefuellter.
7.Dirt,water,orstalefuelisinthefuel system.
8.Thegapbetweenthesafetyinterlock switchesisnotcorrect.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
5.Sparkplugispitted,fouled,orthegap isincorrect.
6.Ventholeinthefuelcapisplugged.6.Cleanorreplacethefuelcap.
7.Dirtinthefuellter.7.Replacethefuellter.
8.Dirt,water,orstalefuelisinthefuel system.
1.Fillfueltankwithgasolineandopen valve
2.Movethechokelevertochokeposition.
3.Installwireonsparkplug.
4.Installanew,correctlygappedspark plug.
5.Servicetheaircleanerelement.
7.ContactanAuthorizedServiceDealer.
8.ContactanAuthorizedServiceDealer.
2.Servicetheaircleaner.
3.Addoiltothecrankcase.
4.Removetheobstructionfromthe coolingnsandairpassages.
5.Installanew,correctlygappedspark plug.
8.ContactanAuthorizedServiceDealer.
Engineoverheats.
Machinedoesnotdrive.
Abnormalvibration.
Unevencuttingheight.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesunder theengineblowerhousingareplugged.
1.Hydraulicoilreservoirlow.1.Addhydraulicoiltothereservoir.
2.Airinthehydraulicsystem.2.Bleedtheairoutthehydraulicsystem.
3.Pumpdrivebeltslipping.3.Replacethepumpdrivebelt.
4.Pumpdrivebeltidlerspringmissing.4.Replacethepumpdrivebeltidler
5.Pumpby-passvalvesareopen.5.Tightentheby-passvalves.
1.Cuttingblade(s)is/arebentor unbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley ,idlerpulley,or bladepulley .
5.Enginepulleyisdamaged.
6.Bladespindleisbent.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerdeckisnotlevel.3.Levelthemowerdeckside-to-side
4.Mowerdeckpitchiswrong.
5.Undersideofmowerdeckisdirty.5.Cleantheundersideofthemower
6.Tirepressureisnotcorrect.6.Adjustthetirepressure.
7.Bladespindlebent.
2.Addoiltothecrankcase.
3.Removetheobstructionfromthe coolingnsandairpassages.
spring.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
position.
4.Adjustthefront-to-rearpitch.
deck.
7.ContactanAuthorizedServiceDealer.
63
Problem
PossibleCauseCorrectiveAction
Bladesdonotrotate.
Themachinedoesnottrackcorrectly .
1.Pumpdrivebeltisworn,looseor broken.
2.Pumpdrivebeltisoffpulley.
3.Mowerdeckbeltisworn,looseor broken.
4.Mowerdeckbeltisoffpulley.
5.Brokenormissingidlerspring.5.Replacethespring.
6.Electricclutchoutofadjustment.
7.Clutchconnectororwiredamaged.7.ContactanAuthorizedServiceDealer.
8.Damagedelectricclutch.
9.Safetyinterlocksystempreventsblade rotation.
10.PTOswitchisfaulty.10.ContactanAuthorizedServiceDealer.
1.Motioncontrolcablesareoutof adjustment.
2.Pumpdrivebeltslippingononepump pulley.
3.Hyraulicpumpby-passvalveispartially open.
1.Checkthebelttension.
2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.
3.Installnewdeckbelt.
4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.
6.Adjusttheclutchairgap.
8.ContactanAuthorizedServiceDealer.
9.ContactanAuthorizedServiceDealer.
1.Adjustthecablesattheadjustmentnut.
2.Installnewpumpdrivebelt.
3.Closetheby-passvalve.T orqueto1 10 to130in-lb(12to15N-m).
64
Schematics
HydraulicSchematic(Rev.A)
65
G015606
ElectricalSchematic(Rev.A)
66
Notes:
67
Notes:
68
Notes:
69
EuropeanPrivacyNotice
TheInformationT oroCollects ToroWarrantyCompany(T oro)respectsyourprivacy .Inordertoprocessyourwarrantyclaimandcontactyouintheeventofaproductrecall,weaskyou tosharecertainpersonalinformationwithus,eitherdirectlyorthroughyourlocalTorodealer.
TheTorowarrantysystemishostedonserverslocatedwithintheUnitedStateswhereprivacylawmaynotprovidethesameprotectionasapplies inyourcountry.
BYSHARINGYOURPERSONALINFORMATIONWITHUS,YOUARECONSENTINGTOTHEPROCESSINGOFYOURPERSONALINFORMATION ASDESCRIBEDINTHISPRIVACYNOTICE.
TheWayT oroUsesInformation Toromayuseyourpersonalinformationtoprocesswarrantyclaimsandtocontactyouintheeventofaproductrecall.Toromayshareyourinformation withToro'safliates,dealersorotherbusinesspartnersinconnectionwithanyoftheseactivities.Wewillnotusepersonalinformationprovidedfor warrantypurposesformarketing,norshallwegiveorsellpersonalinformationprovidedforwarrantypurposestoanyothercompanyformarketing.We reservetherighttodisclosepersonalinformationinordertocomplywithapplicablelawsandwithrequestsbytheappropriateauthorities,tooperateits systemsproperlyorforourownprotectionorthatofotherusers.
RetentionofyourPersonalInformation Wewillkeepyourpersonalinformationaslongasweneeditforthepurposesforwhichitwasoriginallycollectedorforotherlegitimatepurposes (suchasregulatorycompliance),orasrequiredbyapplicablelaw.
Toro'sCommitmenttoSecurityofY ourPersonalInformation Wetakereasonableprecautionsinordertoprotectthesecurityofyourpersonalinformation.Wealsotakestepstomaintaintheaccuracyandcurrent statusofpersonalinformation.
AccessandCorrectionofyourPersonalInformation Ifyouwouldliketorevieworcorrectyourpersonalinformation,pleasecontactusbyemailatlegal@toro.com.
374-0282RevA
IntlDistList
Distributor:
AtlantisSuveSulamaSisstemleriLt BalamaPrimaEngineeringEquip.HongKong85221552163 B-RayCorporation CascoSalesCompany CeresS.A.CostaRica CSSCTurfEquipment(pvt)Ltd.SriLanka CyrilJohnston&Co. EquiverMexico525553995444 FemcoS.A.Guatemala G.Y .K.CompanyLtd. GeomechanikiofAthensGreece GuandongGoldenStarChina HakoGroundandGardenSweden HakoGroundandGarden HayterLimited(U.K.) HydroturfInt.CoDubai HydroturfEgyptLLC IbeaS.P.A. IrriamcPortugal351212388260 IrrigationProductsInt'lPvtLtd.India862283960789 JeanHeybroekb.v .Netherlands3130639461 1 MaquiverS.A.Colombia MaruyamaMfg.Co.Inc. MetraKft Mountelda.s.CzechRepublic MunditolS.A. OslingerTurfEquipmentSA OyHakoGroundandGardenAb ParklandProductsLtd.NewZealand6433493760 Prochaska&Cie RTCohen2004Ltd. Riversa ScSvendCarlsenA/S SolvertS.A.S. SpyprosStavrinidesLimitedCyprus SurgeSystemsIndiaLimited T-MarktLogisticsLtd.Hungary3626525500 ToroAustraliaAustralia61395807355 ToroEuropeBVBABelgium3214562960
Country:
Turkey902163448674
Korea82325512076 PuertoRico7877888383
NorthernIreland442890813121
Japan81726325861
Norway4722907760 UnitedKingdom441279723444 UnitedArabEmirates97143479479 Egypt2025194308 Italy390331853611
Japan81332522285 Hungary3613263880
Argentina541148219999 Ecuador59342396970 Finland35898700733
Austria4312785100 Israel97298617979 Spain Denmark4566109200 France33130817700
India911292299901
PhoneNumber:
5062391 138 94112746100
5024423277
30109350054 862087651338 4635100000
5712364079
420255704220
902497798
35722434131
374-0269RevC
TheToroTotalWarranty
Landscape Contractor Equipment(LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:
ProductsWarrantyPeriod
53cmMowers–Residentialuse 53cmMowers–Commercialuse
Mid-SizeWalk-BehindMowers
Engine2years
GrandStand
®
Mowers
KawaskiEngine2years
KohlerEFIEngine3years
Frame
ZMaster
®
2000SeriesMowers
Engine2years
Frame
ZMaster
®
3000SeriesMowers
Engine2years
Frame
ZMaster
®
5000and6000Series
Mowers
KawaskiEngine2years
KohlerEngine2years
KohlerEFIEngine3years
Frame
ZMaster
®
7000SeriesMowers
Engine2years
Frame
AllMowers
Battery2years
Attachments2years
1
Residentialusemeansuseoftheproductonthesamelotasyourhome.Useatmorethanone
locationisconsideredcommercialuseandthecommercialwarrantywouldapply.
2
SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer.
3
Whicheveroccursrst.
4
LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplacedunderwarrantyatnocostforpartsandlabor .Frame
failureduetomisuseorabuseandfailureorrepairrequiredduetorustorcorrosionarenotcovered.
Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.
1
2years 1year
2years
2
5yearsor1,200hours
Lifetime(originalowneronly)
4yearsor500hours
2
Lifetime(originalowneronly)
5yearsor1,200hours
2
Lifetime(originalowneronly)
5yearsor1,200hours
2
2
2
Lifetime(originalowneronly)
4yearsor1,200hours
2
Lifetime(originalowneronly)
3
4
3
4
3
4
3
4
3
4
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:
1.Contactyoursellertoarrangeserviceoftheproduct.Ifforanyreason itisimpossibleforyoutocontactyourseller,youmaycontactany ToroAuthorizedDistributortoarrangeservice.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:
RLCCustomerCareDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 001-952-948-4650
SeeattachedDistributorList.
OwnerResponsibilities
YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator'sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:
Costofregularmaintenanceserviceorwearparts,suchaslters,
fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.
Anyproductorpartwhichhasbeenalteredormisusedandrequires
replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.
Repairsnecessaryduetoimproperfuel,contaminantsinthefuel
system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.
Allrepairscoveredbythesewarrantiesmustbeperformedbyan
AuthorizedToroServiceDealerusingT oroapprovedreplacement parts.
GeneralConditions
Thepurchaseriscoveredbythenationallawsofeachcountry.Therights towhichthepurchaserisentitledwiththesupportoftheselawsarenot restrictedbythiswarranty.
374-0272RevB
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