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74551
Operator's Manual
64 pgs40.84 Mb0
Parts Catalogue
32 pgs1.12 Mb0
Service Manual
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Setup Instructions
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Toro 74550, 74551, 79549, 79551 Operator's Manual

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Page 1
FormNo.3365-450RevA
GrandStand
®
Mower
Witha48in,52inor60inTURBOFORCE CuttingUnit
ModelNo.74538—SerialNo.310000001andUp
ModelNo.74539—SerialNo.310000001andUp
ModelNo.74548—SerialNo.310000001andUp
ModelNo.74549—SerialNo.310000001andUp
ModelNo.74550—SerialNo.310000001andUp
ModelNo.74551—SerialNo.310000001andUp
ModelNo.79548—SerialNo.310000001andUp
ModelNo.79549—SerialNo.310000001andUp
®
ModelNo.79551—SerialNo.310000001andUp
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.
Theenclosed
Engine Owner’ s Man ual
issupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
Introduction
Thisrotary-blade,ridinglawnmowerisintendedto beusedbyresidentialhomeownersorprofessional, hiredoperators.Itisdesignedprimarilyforcutting grassonwell-maintainedlawnsonresidential orcommercialproperties.Itisnotdesignedfor cuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .T oro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready . identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Figure1
Figure1
1.Locationofthemodelandserialnumbers
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythefollowingwords:
•Dangersignalsanextremehazardthatwillcause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
•Warningsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
•Cautionsignalsahazardthatmaycauseminor ormoderateinjuryifyoudonotfollowthe recommendedprecautions.
Thismanualusestwootherwordstohighlight information.Importantcallsattentiontospecial mechanicalinformationandNoteemphasizesgeneral informationworthyofspecialattention.
Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
ToroMowerSafety...............................................5
SlopeIndicator.....................................................7
SafetyandInstructionalDecals.............................8
ProductOverview......................................................12
Controls.............................................................12
Specications.....................................................13
Operation...................................................................14
AddingFuel.......................................................14
CheckingtheEngineOilLevel............................15
BreakingInaNewMachine................................15
©2010—TheT oro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.T oro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
ThinkSafetyFirst...............................................15
OperatingtheParkingBrake...............................15
OperatingtheMowerBladeControlSwitch
(PTO)............................................................16
OperatingtheThrottle.......................................16
OperatingtheChoke..........................................16
OperatingtheIgnitionSwitch.............................17
UsingtheSpeedControlLever...........................17
UsingtheFuelShut-OffValve............................17
StartingandStoppingtheEngine........................18
TheSafetyInterlockSystem................................19
OperatingthePlatform......................................20
DrivingForwardorBackward.............................21
StoppingtheMachine.........................................22
PushingtheMachinebyHand.............................22
TransportingMachines.......................................23
LoadingMachines..............................................23
SideDischargingorMulchingtheGrass..............24
AdjustingtheHeight-of-Cut...............................24
AdjustingtheAnti-ScalpRollers(60inch
MowerDecksOnly).......................................24
AdjustingtheFlowBafe...................................25
PositioningtheFlowBafe.................................25
UsingtheMid-SizeWeight..................................26
Maintenance...............................................................27
RecommendedMaintenanceSchedule(s)................27
PremaintenanceProcedures....................................28
RaisingtheMowerforAccess.............................28
ReleasetheCushionforRearAccess...................29
Lubrication.............................................................30
HowtoGrease...................................................30
LubricatingtheMachine.....................................30
GreasingtheFrontCasterPivots.........................31
LubricateCasterWheelHubs.............................31
EngineMaintenance...............................................32
ServicingtheAirCleaner....................................32
ServicingtheEngineOil.....................................34
ServicingtheSparkPlug.....................................36
FuelSystemMaintenance.......................................38
DrainingtheFuelTank.......................................38
ServicingtheFuelFilter......................................38
ElectricalSystemMaintenance................................39
ServicingtheBattery...........................................39
ServicingtheFuses.............................................40
DriveSystemMaintenance.....................................41
AdjustingtheTracking.......................................41
CheckingtheTirePressure.................................42
AdjustingtheCasterPivotBearing......................42
ServicingtheCasterWheelandBearings.............42
AdjustingtheElectricClutch..............................43
CoolingSystemMaintenance..................................44
CleaningtheAirIntakeScreen............................44
CleaningtheCoolingSystem...............................44
BrakeMaintenance.................................................45
ServicingtheBrake.............................................45
BeltMaintenance....................................................47
ReplacingtheMowerDeckBelt..........................47
ReplacingthePumpDriveBelt...........................47
ControlsSystemMaintenance.................................48
AdjustingtheMotionControlHandle
Positions........................................................48
HydraulicSystemMaintenance...............................50
ServicingtheHydraulicSystem...........................50
MowerDeckMaintenance......................................53
ServicingtheCuttingBlades...............................53
CorrectingtheMowerQualityofCut..................55
ReplacingtheGrassDeector.............................57
Cleaning.................................................................58
CleaningUndertheMower.................................58
WasteDisposal...................................................58
Storage.......................................................................59
CleaningandStorage..........................................59
Troubleshooting.........................................................60
Schematics.................................................................62
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Safety
Note:Theadditionofattachmentsmadeby
othermanufacturersthatdonotmeetAmerican NationalStandardsInstitutecerticationwillcause noncomplianceofthismachine.
Improperuseormaintenancebytheoperatoror ownercanresultininjury.Toreducethepotential forinjury,complywiththesesafetyinstructions andalwayspayattentiontothesafetyalertsymbol
,whichmeansCAUTION,WARNING,or DANGER-“personalsafetyinstruction."Failureto complywiththeinstructionmayresultinpersonalinjury ordeath.
–Useonlyanapprovedcontainer
–Neverremovegascaporaddfuelwithengine
running.Allowenginetocoolbeforerefueling. Donotsmoke.
–Neverrefuelordrainthemachineindoors.
•Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
•Neverrunanengineinanenclosedarea.
SafeOperatingPractices
ThefollowinginstructionsarefromANSIstandard B71.4-2004.
Training
•ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner’sresponsibilitytoexplain thismaterialtothem.
•Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
•Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.
•Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.
•Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.
Preparation
•Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
•Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.
•Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.
•Useextracarewhenhandlinggasolineandother fuels.Theyareammableandvaporsareexplosive.
•Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.
•Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Onlystartengine fromtheoperator’sposition.
•Besureofyourfootingwhileusingthismachine, especiallywhenbackingup.W alk,don’trun.Never operateonwetgrass.Reducedfootingcouldcause slipping.
•Slowdownanduseextracareonhillsides.Besure totravelsidetosideonhillsides.Turfconditions canaffectthemachine’ sstability.Usecautionwhile operatingneardrop-offs.
•Slowdownandusecautionwhenmakingturnsand whenchangingdirectionsonslopes.
•Neverraisedeckwiththebladesrunning.
•NeveroperatewiththePTOshield,orotherguards notsecurelyinplace.Besureallinterlocksare attached,adjustedproperly,andfunctioningproperly .
•Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.
•Donotchangetheenginegovernorsettingor overspeedtheengine.
•Stoponlevelground,disengagedrives,engage parkingbrake(ifprovided),shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.
•Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.
•Keephandsandfeetawayfromthecuttingunit.
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•Lookbehindanddownbeforebackinguptobesure ofaclearpath.
•Keeppetsandbystandersaway .
•Slowdownandusecautionwhenmakingturnsand crossingroadsandsidewalks.Stopbladesifnot mowing.
•Beawareofthemowerdischargedirectionanddo notpointitatanyone.
•Donotoperatethemowerundertheinuenceof alcoholordrugs.
•Usecarewhenloadingorunloadingthemachine intoorfromatrailerortruck.
•Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
•Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
Maintenanceandstorage
•Disengagedrives,setparkingbrake,stopengineand removekeyordisconnectsparkplugwire.Waitfor allmovementtostopbeforeadjusting,cleaningor repairing.
•Cleangrassanddebrisfromcuttingunit,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.
•Letenginecoolbeforestoringanddonotstorenear ame.
•Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.
•Parkmachineonlevelground.Setparkingbrake. Neverallowuntrainedpersonneltoservicemachine.
•Usejackstandstosupportcomponentswhen required.
•Carefullyreleasepressurefromcomponentswith storedenergy.
•Disconnectthebatteryorremovesparkplugwire beforemakinganyrepairs.Disconnectthenegative terminalrstandthepositivelast.Reconnectthe positiverstandnegativelast.
•Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplaceblades.Neverstraightenorweldthem.
•Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
•Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.
ToroMowerSafety
Thefollowinglistcontainssafetyinformationspecic toToroproductsandothersafetyinformationyoumust know .
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
GeneralOperation
•Besuretheareaisclearofotherpeoplebefore mowing.Stopthemachineifanyoneentersthearea.
•Donottouchequipmentorattachmentpartswhich maybehotfromoperation.Allowtocoolbefore attemptingtomaintain,adjustorservice.
•UseonlyToroapprovedattachments.W arrantymay bevoidedifusedwithunapprovedattachments.
•Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)before operatingunderanyobjectsanddonotcontact them.
•Slowdownbeforemakingturnsanduseextra caution.
•Usecautionwhenridingtheplatformovercurbs, rocks,roots,orotherobstructions.
•Lookbehindanddownbeforebackinguptobesure ofaclearpath.Useextracarewhenoperationin reverse.
•Neverjerkthecontrols;useasteadymotion.
•Whenloadingorunloadingthemachine,useonefull widthrampthatiswideenoughtoextendbeyond thewidthofthemachine.
•Nevercarrypassengers.
•Nevercarrycansorequipmentonthemachine.
SlopeOperation
Allslopesandrampsrequireextracaution.Ifyoufeel uneasyonaslope,donotmowit.
•Removeobstaclessuchasrocks,treelimbs,etc.from themowingarea.
•Watchforholes,rutsorbumps.Tallgrasscanhide obstacles.
•Usecautionneardrop-offs,ditches,orembankments. Themachinecouldsuddenlyturnoverifawheel
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goesovertheedgeofaclifforditch,orifanedge cavesin.
•Useextracarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machine.
•Keepallmovementonslopesslowandgradual.Do notmakesuddenchangesinspeedordirection.
•Mowslopessidetoside.
•Donotmowslopesgreaterthan20degrees.
Service
•Neverstorethemachineorfuelcontainerinside wherethereisanopename,suchasnearawater heaterorfurnace.
•Keepnutsandboltstight,especiallytheblade attachmentbolts.Keepequipmentingood condition.
•Nevertamperwithsafetydevices.Checksafety systemsforproperoperationbeforeeachuse.
•Useonlygenuinereplacementpartstoensurethat originalstandardsaremaintained.
•Checkbrakeoperationfrequently.Adjustandservice asrequired.
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SlopeIndicator
G011841
Figure2
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis20degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan20degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
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SafetyandInstructional Decals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
98-5954
1-403005
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
54-9220
5.ReadtheOperator’s Manual.
6.Keepbystandersasafe distancefromthebattery.
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries
8.Batteryacidcancause blindnessorsevereburns.
withwaterandgetmedical helpfast.
10.Containslead;donot discard.
58-6520
1.Grease
106-5517
1.Warning–DoNottouchthehotsurface.
Manufacturer’sMark
68-8340
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
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110-2067
110-2068
1.ReadtheOperator’sManual.
115-4186
1.Interval
2.PowerT ake-off(PTO)
3.Parkingbrake
4.Neutral
5.Operatorpresenceswitch
6.Battery
115-4212
1.Hydraulicoillevel3.Warning—donottouch
thehotsurface.
2.ReadtheOperator’s Manual.
1.ReadtheOperator’s Manual.
2.Readtheinstructions beforeservicingor performingmaintenance.
112-3858
3.Removetheignitionkey beforeadjustingtheheight ofcut.
4.Heightofcutsettings.
116-3069
116-3076
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117-0456
1.Heightofcut(HOC)—high3.Heightofcut(HOC)—low
2.Heightofcut (HOC)—medium
117-0485
117-0486
1.Tractioncontrol
2.Fast4.Neutral
117-0454
3.Slow
5.Reverse
6.PowerT ake-off (PTO)—disengage
7.Operatorpresenceswitch
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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—disengage4.Fast
2.Parkingbrake—engage
3.Tractioncontrol
119-7245
7.PowerTake-off(PTO)—engage
5.Continuousvariablesetting8.PowerTake-off(PTO)—disengage
6.Slow
9.Enginespeed
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ProductOverview
g012844
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4
5
6
7
8
9
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11
12
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Figure3
1.Sidedischargechute7.Controllevers
2.Battery8.Manualtube
3.Engine
4.Fuelshut-offvalve
5.Fueltank11.Mowerdeck
6.Controls
9.Platform(downposition)
10.Hydraulictank
12.Frontcasterwheel
Figure4
1.Parkingbrakelever8.Fuelcap
2.Choke9.Height-of-cutpin
3.Hourmeter
4.Ignitionswitch11.Throttlecontrol
5.Speedcontrollever
6.Fuelgauge
7.Height-of-cutlever14.Leftmotioncontrollever
10.Platformlatch
12.Rightmotioncontrollever
13.Bladecontrolswitch(PTO)
Controls
Becomefamiliarwithallthecontrols(Figure4)before youstarttheengineandoperatethemachine.
HourMeter
Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance (Figure5).
FuelGauge
Thefuelgaugeislocatedonthetop,middleofthetank
Figure4).
(
SafetyInterlockIndicators
Therearesymbolsonthehourmeterandindicatewith ablacktrianglethattheinterlockcomponentisinthe correctposition(Figure5).
BatteryIndicatorLight
IftheignitionkeyisturnedtotheOnpositionforafew seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure5).
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Figure5
1.Safetyinterlocksymbols
2.Batterylight
3.Hourmeter
SpeedControlLever
Thismachinehasavariablespeedcontrol.Thiscontrols howfastorslowthemachinewilltravel.
ThrottleControl
enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
48inchmowers:
Widthwithdeectordown63.5inches(161.3cm)
Lengthwithplatformdown74inches(188cm)
Lengthwithplatformup58inches(147.3cm)
Height
Weightwith20hpengine
Weightwith24hpengine
48inches(121.9cm)
881(399.6kg)
888(402.8kg)
ThethrottlecontrolisvariablebetweenFastandSlow.
Choke
Usethechoketostartacoldengine.
BladeControlSwitch(PTO)
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.
52inchmowers:
Widthwithdeectordown67.5inches(171.4cm)
Lengthwithplatformdown74inches(188cm)
Lengthwithplatformup58inches(147.3cm)
Height
Weightwith20hpengine
Weightwith24hpengine
60inchmowers:
Widthwithdeectordown75.67inches(192.2cm)
Lengthwithplatformdown74inches(188cm)
Lengthwithplatformup58inches(147.3cm)
Height
Weightwith25hpengine
Weightwith26hpengine
48inches(121.9cm)
883(400.5kg)
900(408.2kg)
48inches(121.9cm)
920(417.3kg)
925(419.5kg)
FuelShut-offValve
Closethefuelshut-offvalve(ontherightsideofthe engine)whentransportingorstoringthemower.
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto
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Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
AddingFuel
UseUnleadedRegularGasolinesuitablefor automotiveuse(85pumpoctaneminimum).Leaded regulargasolinemaybeusedifunleadedregularisnot available.
Important:Neverusemethanol,gasoline containingmethanol,orgasoholcontainingmore than10%ethanolbecausethefuelsystemcouldbe damaged.Donotmixoilwithgasoline.
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Fillthefueltankoutdoorsonlevelground,in anopenarea,whentheengineiscold.Wipeup anygasolinethatspills.
DANGER
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
•Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.
•Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.
•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.
•Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
•Neverllthefueltankinsideanenclosedtrailer.
•Donotllthefueltankcompletelyfull.Fill thefueltanktothebottomofthellerneck. Theemptyspaceinthetankallowsgasolineto expand.Overllingmayresultinfuelleakage ordamagetotheengineoremissionsystem(if equipped).
•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
•Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
WARNING
Gasolineisharmfulorfatalifswallowed. Long-termexposuretovaporscancauseserious injuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepfaceawayfromnozzleandgastankor conditioneropening .
•Keepgasawayfromeyesandskin.
UsingStabilizer/Conditioner
Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
•Keepsgasolinefreshduringstorageof90daysor less.Forlongerstorageitisrecommendedthatthe fueltankbedrained.
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuel system,whichcauseshardstarting
Important:Donotusefueladditives containingmethanolorethanol.
Addthecorrectamountofgas stabilizer/conditionertothegas.
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Note:Afuelstabilizer/conditionerismost
2
4
3
G012565
1
5
effectivewhenmixedwithfreshgasoline.To minimizethechanceofvarnishdepositsinthefuel system,usefuelstabilizeratalltimes.
FillingtheFuelT ank
Note:Donotllthefueltankcompletelyfull.Fillthe
fueltanktothebottomofthellerneck.Theempty spaceinthetankallowsthegasolinetoexpand.
1.Parkthemachineonlevelground.
2.Shuttheengineoffandsettheparkingbrake.
3.Cleanaroundthefueltankcap.
4.Fillthefueltanktothebottomofthellerneck. Ensurethereisemptyspaceinthetanktoallowthe gasolinetoexpand
Figure6.
BreakingInaNewMachine
Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew, placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.
ThinkSafetyFirst
Carefullyreadallthesafetyinstructionsanddecalsin thesafetysection.Knowingthisinformationcould helpyouoranybystandersavoidinjury.
Theuseofprotectiveequipmentforeyes,hearing,feet andheadisrecommended.
CAUTION
Thismachineproducessoundlevelsinexcessof 85dBAattheoperator’searandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Figure6
OperatingtheParkingBrake
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.Beforeeachuse,check theparkingbrakeforproperoperation.
Iftheparkingbrakedoesnotholdsecurely,adjustit. RefertoServicingtheParkingBrake.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhileit isunattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
SettingtheParkingBrake
Pulltheparkingbrakeleverrearwardandoverinto engagedposition(Figure7).
CheckingtheEngineOilLevel
Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking OilLevelinEngineMaintenance.
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Figure7
G008945
G009174
G008946
1.Parkingbrakeengaged2.Parkingbrakereleased
Figure9
OperatingtheThrottle
ReleasingtheParkingBrake
Pullthebrakeleverbackandoverintotheslotand 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.
ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure10).
Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).
Figure10
OperatingtheChoke
Usethechoketostartacoldengine.
1.Iftheengineiscold,usethechoketostartthe engine.
Figure8
DisengagingtheMowerBlades(PTO)
Thefollowingaretwooptionsfordisengagingthe mowerblades.
•Pushthebladecontrolswitch(PTO)downtothe offposition.
•Movethemotioncontrolleverstoneutralandmove therightsidemotioncontrolleverintotheneutral lockposition.
2.Pulluponthechokeknobtoengagethechoke beforeusingtheignitionswitch(
Figure11).
3.Pushdownonthechoketodisengagethechoke aftertheenginehasstarted(Figure11).
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G008959
1
2
Figure11
START
RUN
STOP
G008947
1.On2.Off
UsingtheSpeedControl Lever
Thismachinehasaspeedcontrolleverthatsets themaximumgroundspeedofthemachine.This canbeadjustedtotheoperator’sdesiredspeed.It isrecommendedtousetheslowestspeedfornew operator’s.
1.Movethespeedcontrollevertosetthedesired speed.
•Fullforwardhasquickresponseandmaximum speed.
•Fullrearwardhassmoothresponseandslower speed.
2.Movethecontrolleverstodrivethemachine.The controlleversmaybepushedforwardtothefront referencebarwhilethespeedofthemachineis controlledbythespeedcontrollever.
OperatingtheIgnitionSwitch
1.TurntheignitionkeytotheStartposition (Figure12).Whentheenginesstarts,releasethekey.
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Figure13
Note:Additionalstartingcyclesmayberequired
whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.
UsingtheFuelShut-OffValve
Closethefuelshut-offvalvefortransport,maintenance, andstorage(
Ensurethefuelshut-offvalveisopenwhenstarting theengine.
Figure14).
Figure12
2.Turntheignitionkeytostoptostoptheengine.
17
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G008948
1
2
Figure14
START
RUN
STOP
G008947
1.On2.Off
StartingandStoppingthe Engine
StartingtheEngine
1.Connectthewirestothesparkplugs.
2.Openthefuelvalve.
3.Movetherightmotioncontrollevertoneutral lockedposition.
4.Settheparkingbrake;refertoSettingtheParking Brake.
Figure15
7.TurntheignitionkeytotheStartposition (Figure12).Whentheenginesstarts,releasethekey.
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.
5.Movethebladecontrolswitch(PTO)totheOff position.
Figure16
6.MovethethrottlelevermidwaybetweentheSlow andFastpositions.
1.Off3.Start
2.Run
Note:Awarmorhotenginemaynotrequire choking.
18
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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.
Figure17
Important:Makesurefuelshutoffvalveisclosed
beforetransportingorstoringthemachine,asfuel leakagemayoccur.Beforestoringthemachine, pullwireoffsparkplug(s)topreventpossibilityof accidentalstarting.
Figure18
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
TestingtheSafetyInterlockSystem
ServiceInterval:Beforeeachuseordaily
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.
Note:Ifthesafetysystemdoesnotoperateas describedbelow,haveanAuthorizedServiceDealer repairthesafetysystemimmediately .
1.Starttheengine;refertoStartingandStoppingthe EngineinOperation(page14).
2.Settheparkingbrake.
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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.
OperatingtheMachinewiththe PlatformUp
Operatingthemachinewiththeplatformupis recommendedwhen:
•Mowingneardrop-off’s
•Mowingsmallareaswherethemachineistoolong
•Areaswithlowoverhangingbranchesorobstacles
•Loadingthemachinefortransport
•Drivingupslopes
Toraisetheplatform,pullthebackoftheplatformup sothelatchpinandknoblockitintoplace.Pushittight againstthecushionforthelatchpintolockintoplace.
OperatingtheMachinewiththe PlatformDown
Operatingthemachinewiththeplatformdownis recommendedwhen:
•Mowingmostareas
•Drivingacrossslopes
•Drivingdownslopes
Tolowertheplatform,pushtheplatformforward againstthecushiontoreleasepressureonthelatchpin andthenpulltheknoboutandlowertheplatform.
WARNING
Theoperatorplatformisheavyandmaycause injurywhenloweringandraisingtheoperator platform.Theplatformmaysuddenlydropifnot supportedwhenthelatchpinispulledout.
•Donotputhandsorngersintheplatform pivotareawhenloweringorraisingtheoperator platform.
•Makesuretheplatformissupportedwhenthe latchpinispulledout.
•Makesurethelatchsecurestheplatformwhen foldingitintheupposition.Pushittight againstthecushionforthelatchpintolock intoplace.
•Keepbystandersawaywhenraisingorlowering theplatform.
OperatingthePlatform
Themachinecanbeusedwiththeplatformintheup ordownposition.Itistheoperator’spreferenceon whichpositiontouse.
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Figure19
G012182
4
5
1
2
3
3 4
1.Platformup
2.Platformdown
3.Pulltheknobouttorelease theplatform
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
Figure20
1.Frontreferencebar
2.Leftcontrollever
3.Rearreferencebar
4.Rightcontrollever
5.Rightcontrolleverinthe neutrallockposition
3.Togoforward,movethespeedcontrollevertothe desiredspeed.
4.Slowlypushthemotioncontrolleversforward (Figure21).
Note:Theenginewillkillifamotioncontrollever ismovedwiththeparkingbrakeengaged.
Thefartheryoumovethemotioncontrolleversin eitherdirection,thefasterthemachinewillmovein thatdirection.
Tostop,pullthemotioncontrolleversbacktothe neutralposition.
CAUTION
Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.
Slowthemachinedownbeforemakingsharpturns.
DrivingForward
1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
2.Movetherightsidemotioncontrollevertothe center,un-lockedposition.
21
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Figure21
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
Figure22).
(
Figure22
ToPushtheMachine
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
2.Opentheby-passvalveonbothpumpsbyturning themcounterclockwise1to2turns.Thisallows hydraulicuidtoby-passthepumpsandthewheels toturn(
Note:Rotatetheby-passvalvesamaximumof2 turnssothevalvedoesnotcomeoutofthebody causinguidtorunout.
Figure23).
StoppingtheMachine
Tostopthemachine,movethemotioncontrolleversto neutral,movetherightsidemotioncontrolleverinto theneutrallockposition,disengagethepowertakeoff (PTO),andturntheignitionkeytooff.
Figure23
1.Pumpby-passvalve
3.Releasetheparkingbrake.
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4.Pushthemachinetothedesiredlocation.
5.Settheparkingbrake.
6.Closetheby-passvalves,butdonotovertighten them.
Important:Donotstartoroperatethe machinewiththeby-passvalvesopen.Damage tosystemmayoccur.
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.
5.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.
6.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(
Figure24).
extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit(Figure25). 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.
Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.
Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.
Figure25).Asteeperangle
WARNING
Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.
Figure24
1.Tractionunittiedownloop
LoadingMachines
Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto
•Useextremecautionwhenoperatingauniton aramp.
•Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.
•Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.
•Donotexceeda20degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.
•Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.
•Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.
23
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Figure25
1.Trailer3.Notgreaterthan 20degrees
2.Fullwidthramp4.Fullwidthramp—sideview
SideDischargingorMulching
1.Movetheheight-of-cutlevertothetransport position(allthewayup).
2.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(Figure26).
3.Lowertheheight-of-cutlevertothepin(Figure26).
Figure26
1.Height-of-cutholes3.Height-of-cutlever
2.Height-of-cutpin
theGrass
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).
AdjustingtheAnti-Scalp Rollers(60inchMowerDecks Only)
Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.
1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethenutandboltpositiontheanti-scalp rollersandinstallthenutandbolt.Ensurethe spacersandbushingsareinstalledasshown.
AdjustingtheHeight-of-Cut
Theheight-of-cutcanbeadjustedfrom1to5inches (25to127mm)in1/4inch(6mm)increments.
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Figure27
1.Bushing4.Bolt
2.Anti-scalproller5.Nut
3.Spacer
AdjustingtheFlowBafe
Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlockand bafetogivethebestqualityofcut.
1.DisengagethePTO,movethemotioncontrol leverstotheneutrallockedpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthecamlock,swingtheleveruptoloosen thecamlock(
Figure28).
Figure28
1.Camlock
2.Lever
3.Rotatecamtoincreaseor decreaselockingpressure
4.Slot
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
PositionA
Thisisthefullrearposition(seeFigure29).The suggesteduseforthispositionisafollows.
•Useforshort,lightgrassmowingconditions.
•Useindryconditions.
•Forsmallergrassclippings.
4.Adjustthebafeandcamlockintheslottothe desireddischargeow .
5.Swingtheleverbackovertotightenthebafeand camlock(Figure28).
6.Ifthecamdoesnotlockthebafeintoplaceoritis tootight,loosentheleverandthenrotatethecam lock.Adjustthecamlockuntilthedesiredlocking pressureisachieved.
•Propelsgrassclippingsfartherawayfromthe mower.
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Figure29
Figure31
PositionB
Usethispositionwhenbagging(Figure30).
Figure30
PositionC
UsingtheMid-SizeWeight
•Weightsareinstalledtoimprovehandling,balance andimproveperformance.Weightscanbeaddedor removedtocreateoptimizedperformanceunder differentmowingconditionsandforoperator preference.
•Itisrecommendedthatweightsbeaddedor removedoneatatimeuntilthedesiredhandingand balanceisachieved.
Note:ContactanAuthorizedServiceDealertoorder aW eightKit.
WARNING
Excessiveweightchangescaneffecthandlingand operationofthemachine.Thiscouldcauseserious injurytoyouorbystanders.
Makeweightchangesissmallincrementsonly .
Evaluatethemoweraftereachweightchangeto ensurethemachinecanbeoperatedsafely.
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows(Figure31).
•Useintall,densegrassmowingconditions.
•Useinwetconditions.
•Lowerstheenginepowerconsumption.
•Allowsincreasedgroundspeedinheavyconditions.
•ThispositionissimilartothebenetsoftheT oro SFSmower.
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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.
•Greasetheliftlinkage(moreoftenindirtyordustyconditions).
•Lubricatethespeedcontrollinkagerollers(moreoftenindirtyordustyconditions).
•Checkthepaperaircleanerelement.
•Checkthetirepressure.
•Checkthehydraulicuidlevel.
•Changetheengineoil.(moreoftenindirtyordustyconditions)
•Check,cleanandregapthesparkplug.
•Checkthebattery.
•Checkandcleanenginecoolingnsandshrouds.
•Checkthemowerdeckbelt.
•Checkthepumpdrivebelt.
•Checkthehydraulichoses.
Every200hours
Every250hours
Every500hours
Every800hours
Beforestorage
Yearly
Important:Refertoyour
•Greasethemowerdeckspindles(moreoftenindirtyordustyconditions).
•Replacethepaperaircleanerelement.
•Changetheengineoillter.
•ChangethehydrauliclterandhydraulicoilwhenusingMobil®1oil.
•Adjustthecasterpivotbearing.
•Checktheelectricclutch.
•ChangethehydrauliclterandhydraulicoilwhenusingT oro®HYPR-OIL™500 hydraulicoil.
•Changethehydrauliclter.
•Greasethefrontwheelbearings(moreoftenindirtyordustyconditions).
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Replacethefuellter.
•Paintchippedsurfaces.
•Performallmaintenanceprocedureslistedabovebeforestorage.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Lubricatethecasterwheelhubs
Engine Operator’ s Man ual
foradditionalmaintenanceprocedures.
27
Page 28
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthesparkplugwiresfromthesparkplugsbeforeyoudo anymaintenance.Setthewiresasidesothattheydonotaccidentallycontactthesparkplugs.
Premaintenance Procedures
RaisingtheMowerforAccess
Thefrontofthemowercanberaisedandsupportedon itsbackforaccessunderthemachineformaintenance.
1.Raisetheplatform.RefertoOperatingthePlatform inOperation.
2.Removethebattery.
Figure32
1.Wingnut4.Positivebatterycable
2.Batterycover5.Battery
3.Negativebatterycable
3.Drainthefuelfromthefueltank.RefertoDraining theFuelTankinMaintenance.
4.Removethecapofthehydraulictankandplace apieceofplasticovertheopeningandinstallthe hydrauliccap.Thiswillsealthehydraulictankand preventitfromleakingout.
Figure33
1.Cap
2.Pieceofplastic
5.Withtwopeople,raisethefrontofthemowersoit restsonthedrivetiresandtheplatformintheup position.
6.Performanymaintenanceonthemachine.
7.Withtwopeople,lowerthefrontofthemowerto theground.
8.Removetheplasticunderthehydraulictankcap.
9.Installthebatteryforthemachine.
3.Hydraulictank
28
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Figure34
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(Figure35).
1.Plasticbushingwithlarge washer
2.Cushionbracketwithkey hole
Figure35
3.Hairpincotterpin
7.Slidethelargewashersplasticbushingsintothe cushionbracketandsecurethemwithahairpin cotterpin(
Figure35).
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Page 30
Lubrication
GreasewithNo.2generalpurposelithiumbaseor molybdenumbasegrease.
Lubricatethetractionrollerswithadrylubricant (PTFE).
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.
Figure36
LubricatingtheMachine
ServiceInterval:Every50hours—Greasethelift
linkage(moreoftenindirtyordusty conditions).
Every50hours—Lubricatethespeed controllinkagerollers(moreoftenin dirtyordustyconditions).
Every200hours—Greasethemower deckspindles(moreoftenindirtyor dustyconditions).
Every800hours/Y early(whichever comesrst)—Greasethefrontwheel bearings(moreoftenindirtyordusty conditions).
Every800hours/Y early(whichever comesrst)—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).
Usethefollowinggraphicsforlocatingthegreasepoints.
Figure37
Figure38
Lubricatethespeedcontrollinkagerollerswithadry PTFE(Polytetrauoroethylene)lubricant.
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Important:UseonlyadryPTFE
g013192
(Polytetrauoroethylene)lubricant.Donot useawetoillm,whichwillattractdustanddirt.
Figure40
1.Sealguard2.Spacernutwithwrench ats
Figure39
GreasingtheFrontCaster Pivots
ServiceInterval:Yearly
Lubricatethefrontcasterpivotsonceayear.
1.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance Section.
2.Removethehexplug.Threadagreasezerkintothe hole.
3.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.
4.Removethegreasezerkinthehole.Installthehex plugandcap.
LubricateCasterWheelHubs
ServiceInterval:Yearly
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)fromthe outersurfaceofthespacernuttotheendoftheaxle insidethenut.
9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.
1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.
10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
11.Insertthesecondbearingandnewsealintothe wheel.
12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.
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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(FHModelEngines)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage
Figure41).
(
4.Unscrewthecoverknobandremovetheaircleaner cover(
Figure41).
5.Removethewingnutsandremovetheaircleaner assembly(Figure41).
6.Carefullypullthefoamelementoffthepaper element(
Figure41).
32
Page 33
Figure42
FSModelEngineShown
Figure41
FHModelEngineShown
1.Engine4.Foamelement
2.Cover
3.Wingnut
5.Paperelement
6.Coverknob
RemovingtheFoamandPaper Elements(FSModelEngines)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanaroundtheaircleanertopreventdirt fromgettingintotheengineandcausingdamage
Figure42).
(
4.Unscrewthecoverknobsandremovetheaircleaner cover(Figure42).
5.Unscrewthehoseclampandremovetheaircleaner assembly(Figure42).
6.Carefullypullthefoamelementoffthepaper element(Figure42).
1.Cover
2.Hoseclamp4.Foamelement
3.Paperelement
CleaningtheFoamAirCleanerElement
ServiceInterval:Every25hours
1.Washthefoamelementinliquidsoapandwarm water.Whentheelementisclean,rinseitthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifitis tornorworn.
ServicingthePaperAirCleaner Element
ServiceInterval:Every50hours—Checkthepaperair
cleanerelement.
Every200hours—Replacethepaper aircleanerelement.
1.Donotcleanthepaperlter,replaceit(
Figure41).
2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.
3.Replacethepaperelementifitisdamaged.
InstallingtheFoamandPaperElements
Important:Topreventenginedamage,always
operatetheenginewiththecompletefoamand paperaircleanerassemblyinstalled.
1.Carefullyslidethefoamelementontothepaperair cleanerelement(Figure41).
33
Page 34
2.Placetheaircleanerassemblyontotheaircleaner baseorhoseandsecureit(Figure41).
3.Placetheaircleanercoverintopositionandtighten thecoverknob(Figure41).
ServicingtheEngineOil
CheckingtheEngineOilLevel
Note:Checktheoilwhentheengineiscold.
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
ServiceInterval:Beforeeachuseordaily—Checkthe
engineoillevel.
Aftertherst8hours—Changethe engineoil.
Every100hours—Changetheengine oil.(moreoftenindirtyordusty conditions)
Every200hours—Changetheengine oillter.
Note:Changetheoilmorefrequentlywhenthe operatingconditionsareextremelydustyorsandy.
Note:Therearedifferentoilcapacitiesforthedifferent modelslistedinthismanual.Ensurethecorrectamount ofoilisused.
Important:Remembertoadd80%oftheoiland thengraduallyllittothefullmarkonthedipstick.
OilType:Detergentoil(APIserviceSF,SG,SH,SJ
orSL)
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).
CrankcaseCapacityfor20hpand25hpEngines:
58ounces(1.7liter)withthelterremoved;51ounces (1.5liter)withoutthelterremoved
CrankcaseCapacityfor24hpand26hpEngines:
71ounces(2.1liter)withthelterremoved;61ounces (1.8liter)withoutthelterremoved
Viscosity:Refertothetablebelow
Figure43
34
Page 35
G008792
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2
5
6
7
3
9
10
4
8
3.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
4.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position(
Figure45).
Figure44
ChangingtheEngineOil
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.
Figure45
5.Slowlypourapproximately80%ofthespeciedoil intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(
Figure46).
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoassuretheoildrains completely.
35
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G008796
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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.
Figure47
Note:Ensuretheoilltergaskettouchestheengine
andthenanextra3/4turniscompleted.
4.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.
3.Changetheengineoillter(
Figure47).
ServicingtheSparkPlug
ServiceInterval:Every100hours
Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.
TypeforallEngines:NGK
AirGap:0.030inch(0.75mm)
36
®
BPR4ESorequivalent
Page 37
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).
37
Page 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.
ReplacingtheFuelFilter
ServiceInterval:Every800hours/Yearly(whichever
comesrst)
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).
2.Cleanaroundthefuelcaptopreventdebrisfrom gettingintothefueltank(Figure52).
3.Removethefuelcap.
4.Insertasyphonpumpintothefueltank.
5.Usingthesyphonpump,drainthefuelintoaclean gascan(
6.Wipeupanyspilledfuel.
1.Fuelcap
Figure51).
Figure51
Figure52
1.Hoseclamp3.Filter
2.Fuelline
5.Removethelterfromthefuellines.
6.Installanewlterandmovethehoseclampsclose tothelter.
7.Openthefuelshut-offvalve.
8.Checkforfuelleaksandrepairifneeded.
9.Wipeupanyspilledfuel.
38
Page 39
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.Lifttheblackrubbercoveronthenegativecable. 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( overthepost.
Figure53).Slidetherubbercover
•Whenremovingorinstallingthebattery ,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
39
Page 40
Figure53
1.Wingnut4.Positivebatterycable
2.Batterycover5.Battery
3.Negativebatterycable
Figure54
1.PositiveBatteryPost
2.NegativeBatteryPost
3.Red(+)ChargerLead
4.Black(-)ChargerLead
ServicingtheFuses
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance.Ifafuseblows,checkthecomponent orcircuitforamalfunctionorshort.
1.Releasethecushionfromtherearofthemachine.
2.Pulloutonthefusetoremoveorreplaceit Figure55).
(
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).
1.Removethebatteryfromthechassis;referto RemovingtheBattery.
2.Checktheelectrolytelevel;refertoCheckingthe ElectrolyteLevel.
3.Makesurethellercapsareinstalledinbattery. Chargebatteryfor1hourat25to30ampsor6 hoursat4to6amps.
4.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(Figure54).
5.Installthebatteryontothemachineandconnectthe batterycables,refertoInstallingtheBattery.
3.Installthecoverunderthecusion.
Note:Ensurethecorrectsizefuseisinstallwiththe correctwirecolorasshownin
Figure55.
Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.
40
Page 41
DriveSystem
g013168
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Maintenance
AdjustingtheTracking
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
1.Pushbothcontrolleversforwardthesamedistance.
2.Checkifthemachinepullstooneside.Ifitdoes, stopthemachineandsettheparkingbrake.
3.Releasethecushionfromtherearofthemachine.
4.Rotatetherightcableadjustmenttopositionthe rightmotioncontrolinthecenterofthecontrol panelneutrallockslot.Then,rotatetheleftcable adjustmenttomatchtheleftwheelspeedtothe previouslysetrightwheelspeed.(
5.Rotatetheleftcableadjustmenttomatchtheleft
Figure55
1.Controls
2.Wire
3.Fuses
wheelspeedtothepreviouslysetrightwheelspeed. Adjustinquarter-turnincrementsuntilthemachine tracksstraight.
Figure56).
Note:Onlyadjusttheleftcabletomatchtheleft wheelspeedtotherightwheelspeed.Donotadjust therightwheelspeedasthiswillpositiontheright motioncontrolleveroutofthecenterforthecontrol panelneutrallockslot.
6.Checkforpropertracking.
Figure56
1.Leftcableadjustment3.Platformdown
2.Rightcableadjustment
7.Repeatadjustmentuntilthetrackingiscorrect.
8.Checkthatthemachinedoesnotcreepfromneutral withtheparkbrakesdisengaged.
Important:DoNotrotatethelinkagetoofar,as thismaycausethemachinetocreepinneutral.
41
Page 42
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat12-14psi (83-97kPa).Uneventirepressurecancauseanuneven cut.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
Figure58
1.SpringWashers3.DustCap
2.LockNut
Figure57
AdjustingtheCasterPivot Bearing
ServiceInterval:Every500hours/Yearly(whichever
comesrst)
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethedustcapfromcasterandtightenlock
Figure58).
nut(
4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(
Figure58).
ServicingtheCasterWheel andBearings
Thecasterwheelsrotateonarollerbearingsupportedby aspannerbushing.Ifthebearingiskeptwelllubricated, wearwillbeminimal.Failuretokeepthebearingwell lubricatedwillcauserapidwear.Awobblycasterwheel usuallyindicatesawornbearing.
1.Removethelocknutandwheelboltholdingthe casterwheeltothecasterfork(
Figure59).
Important:Makesurespringwashersare installedcorrectlyasshownin
5.Installthedustcap(Figure58).
Figure58.
1.Locknut
2.WheelBolt5.RollerBearing
3.Bushing
42
Figure59
4.SpannerBushing
Page 43
2.Removeonebushing,thenpullthespannerbushing androllerbearingoutofthewheelhub(Figure59).
3.Removetheotherbushingfromthewheelhub andcleananygreaseanddirtfromthewheelhub
Figure59).
(
4.Inspecttherollerbearing,bushings,spannerbushing andinsideofthewheelhubforwear.Replaceany defectiveorwornparts(Figure59).
5.Toassemble,placeonebushingintothewheelhub. Greasetherollerbearingandspannerbushingand slidethemintothewheelhub.Placethesecond bushingintothewheelhub(
Figure59).
6.Installthecasterwheelintothecasterforkand securewiththewheelboltandlocknut.Tightenthe locknutuntilthespannerbushingbottomsagainst theinsideofthecasterforks(
Figure59).
7.Greasethettingonthecasterwheel.
AdjustingtheElectricClutch
Figure60
1.Adjustingnut3.Feelergauge
2.Slot
ServiceInterval:Every500hours—Checktheelectric
clutch.
Theclutchisadjustabletoensureproperengagement andproperbraking.
1.Inserta0.015–0.021inch(0.381-0.533mm)feeler gaugethroughoneinspectionslotinthesideofthe assembly.Makesureitisbetweenthearmatureand therotorfrictionsurfaces.
Thegapneedstobeatleast.015inches(0.381mm) andnotmorethan.021inches(0.533mm).
2.Ifadjustmentisneeded,thensetat.015inches(0.381 mm)foreachofthethreeadjustmentslotpositions. Tightenthelocknutsuntilthereisslightbindingon thefeelergaugebutitcanbemovedeasilywithinthe airgap(
Figure60).
3.Repeatthisfortheremainingslots.
4.Checkeachslotagainandmakeslightadjustments untilthefeelergaugebetweentherotorandarmature withveryslightcontactbetweenthem.
43
Page 44
CoolingSystem 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.
1.Guard
2.Engineairintakescreen
3.Bolt
Figure61
4.Fanhousing
5.Screw
3.Removetheairintakescreenandfanhousing
Figure61).
(
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installairintakescreen,recoilstarterandfanhousing (Figure61).
44
Page 45
BrakeMaintenance
g012808
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2
3
4
5
6
ServicingtheBrake
Beforeeachuse,checkbrakesonbothalevelsurface andslope.
Alwayssettheparkingbrakewhenyoustopthemachine orleaveitunattended.Iftheparkingbrakedoesnot holdsecurely,anadjustmentisrequired.
CheckingtheParkingBrake
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengagethe PTO.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Releasethebrake.Thebrakebarsshouldliftoff thetiresandthehandlevershouldtravelforwardto theendoftheslotinthecontrolpanel.Adjustthe brakeifneeded.
4.Engagethebrakeleveruntilthebrakebarsrst contactthetire(
Figure62).
5.Measurethegapfromthefrontofthehandlever totheendoftheslotinthecontrolpanelwhenthe brakebarcontactsthetire.Thismeasurementneeds tobe3/4inch(19mm).Adjustthebrakeifneeded
Figure62).
(
Figure62
1.Handlever
2.Frontofhandlever
3.3/4inch(19mm)gap
4.Frontofslot
5.Brakebar
6.Brakebarjusttouching thetire
AdjustingtheBrakes
Iftheparkingbrakedoesnotholdsecurely,an adjustmentisrequired.
1.Checkthebrakebeforeyouadjustit;referto CheckingtheBrakes.
2.Parkthemachineonalevelsurface,disengagethe PTO,andsettheparkingbrake.
3.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeOperation.
5.Toadjustthebrake,removethehairpincotter andclevispinfromthelowerbrakeleverandyoke
Figure63).
(
45
Page 46
6.Loosenthejamnut(Figure63).
g013191
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2 3
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5 6
g012873
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3
7.Rotatetheyoke.Totightenthebrake,rotatethe yokeup.Toloosenthebrake,rotatetheyokedown
Figure63).
(
8.Securetheyoketolowerbrakeleverwiththehairpin cotterpinandclevispin(Figure63).
9.Tightenthejamnut(Figure63).
10.Checkthebrakeoperationagain;refertoChecking theBrake.
1.1/8inch(3mm)gap neededbetweenswitch andbrakelever
2.Brakelever
3.Switch
Figure64
4.Switchbutton
5.Faceoftheswitch
Figure63
1.JamNut4.Hairpincotterpin
2.Yoke5.Flatwasher
3.Clevispin
6.Lowerbrakelever
11.Afterthebrakeisadjusted,theleverswitchneeds tobechecked.
12.Checkthegapbetweenthebrakeleverandtheface oftheswitchasshownin
Figure64.Thegapneeds
tobean1/8inch(3mm)withthebrakeengaged.
13.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch.
46
Page 47
BeltMaintenance
ReplacingtheMowerDeck Belt
ServiceInterval:Every100hours—Checkthemower
deckbelt.
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofaworndeckbelt.Replacethedeckbeltif anyoftheseconditionsareevident.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Unlatchandremovethebeltcovers.
4.Loosenthefrontidlerpulleybylooseningthenut.
5.Removethewornmowerbelt(
6.Installthenewmowerbeltaroundthedeckpulleys andclutchpulley(
7.Usingaratchetintheidlerarm,tightentheidler pulleyuntilthespringisstretched5-3/4inches(14.6 cm)fromhooktohook(Figure65).
8.Tightenthefrontidlerpulleybytighteningthenut.
9.Installthebeltcoversontothecuttingunitand securethelatches.
Figure65).
Figure65).
Figure65
1.5-3/4inches(14.6cm) fromhooktohook
2.Spring5.Squareholeforratchet
3.Springloadedidler
4.Ratchet
6.Nut
ReplacingthePumpDriveBelt
ServiceInterval:Every100hours—Checkthepump
drivebelt.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethemowerdeckbelt.
4.Tiltthemachineonit’sback.Referto Pre-Maintenanceatthebeginningofthe MaintenanceSection.
5.Releasethespringfromtheenginedeck(
47
Figure66).
Page 48
Figure66
1.Hydraulicpumps
2.Idlerpulley5.Pumpdrivebelt
3.Clutchpulley
6.Removethepumpdrivebelt(Figure66).
7.Installthenewbeltaroundclutchandthetwopump pulleys.
8.Installthespringtotheenginedeck(Figure66).
4.Clutchretainer
ControlsSystem Maintenance
AdjustingtheMotionControl HandlePositions
AdjustingtheRightSideMotionControl Lever
Ifthemotioncontrolleversdonotalignhorizontally, adjusttherightsidemotioncontrollever.
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
1.DisengagethePTO,movetherightsidemotion controllevertotheneutralpositionandsetthe parkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Pushtherightmotioncontrolleverdownoutof lockedneutralposition(
4.Checkifitalignshorizontallywiththeleftmotion controllever(Figure67).
Figure67).
9.Lowerthemachinetotheoperatingposition. RefertoPre-Maintenanceatthebeginningofthe MaintenanceSection.
10.Installthemowerdeckbelt.
Figure67
1.Leftmotioncontrollever3.Checkthehorizontal
2.Rightmotioncontrollever inneutrallockedposition
5.Toadjusttherightmotioncontrolleverhorizontally, thecamneedstobeadjusted.
6.Releasethecushionfromtherearofthemachine.
7.Loosenthenutandboltholdingthecam(Figure68).
8.Adjustthecamuntilitalignswiththeleftmotion controlleverandtightenthenutandboltforthe cam.
alignmenthere
4.Rightmotioncontrollever
48
Page 49
1.Switchscrews
2.Cam
Figure68
3.Nutandbolt
9.Afterthecamisadjusted,theleverswitchneedsto bechecked.
10.Checkthegapbetweenthecontrolleverandswitch asshowninFigure69.Thegapneedstobean1/8 inch(3mm)withtherightmotioncontrolleverin theneutral,unlockedposition.
11.Ifneeded,loosenthescrewsholdingtheswitchand adjusttheswitch(
Figure68andFigure69).
Figure69
1.Switch
2.1/8inch(3mm)
3.Rightmotioncontrollever intheneutralunlocked position
12.Tightentheswitchscrews.
AdjustingtheNeutralPostionforthe MotionControlLevers
Important:Ensurethetrackingofthemoweris
correctafteradjustingthemotioncontrollevers. Adjustingthetrackingandaligningthemotion controlleversfronttobackisthesameprocedure (Figure70).
Note:Adjustthehorizontalalignmentbeforethefront tobackalignment.
Ifthemotioncontrolleversdonotalignfronttoback, ortherightsidecontrolleverdoesnotmoveeasilyinto theneutrallockposition,adjustmentisrequired.
1.Afterthehorizontalalignmentisnished,checkthe fronttobackalignment(Figure70).
49
Page 50
g013168
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HydraulicSystem
G012005
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Maintenance
ServicingtheHydraulic System
Figure70
1.Leftmotioncontrollever
2.Rightmotioncontrollever4.Alignthecontrollevers
3.Neutrallockedposition
fronttoback
2.Rotatetherightcableadjustmenttoplacetheright motioncontrolleverinthecenteroftheneutrallock slotinthecontrolpanel.
3.Rotatetheleftcableadjustmenttoplacetheleft motioncontrolleveralignmentequalwiththe rightmotioncontrollever.Thiswillprovidean approximateequaltrackingoftheleftwheelspeed totherightwheelspeed.
4.Checkforpropertracking.RefertoAdjustingthe TrackingintheMaintenanceSection.
HydraulicOilType:Toro hydraulicoilorMobil
®
HYPR-OIL
®
115W-50syntheticmotoroil.
™
500
HydraulicSystemOilCapacity:67oz.(2.0l)
Important:Useoilspecied.Otheruidscould causesystemdamage.
CheckingtheHydraulicFluid
ServiceInterval:Aftertherst8hours
Every50hours
Note:Therearetwowaysofcheckingthehydraulicoil. Oneiswhentheoiliswarmandoneiswhentheoilis cold.Thebafeinsidethetankhastwolevelsdepending iftheoiliswarmorcold.
1.Positionmachineonalevelsurface.
2.Disengagethepowertakeoff(PTO)andshutoff theengine.
3.Waitforallmovingpartstostopbeforeleavingthe operatingpositionandthensettheparkingbrake.
Figure71
1.Leftcableadjustment3.Platformdown
2.Rightcableadjustment
4.Cleanareaaroundcapandllerneckofhydraulic tank(Figure72).
Figure72
1.Cap3.Colduidlevel-full
2.Bafe4.Hotuidlevel-full
5.Removecapfromllerneck.Lookinsidetocheck theuidlevelinthereservoir.(Figure72).
6.Adduidtothereservoiruntilitreachesthecold levelofthebafe.
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7.Runthemachineatlowidlefor15minutestoallow
G011641
1 2
3
anyairtopurgeoutofthesystemandwarmuid. RefertoStartingandStoppingtheEngine.
8.Rechecktheuidlevelwhiletheuidiswarm.If required,adduidtothereservoiruntilitreaches thehotlevelofthebafe.
Note:Theuidlevelshouldbetothetopofthehot levelofthebafe,whentheuidiswarm(Figure72).
9.Installcaponllerneck.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskin itmustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
•Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.
3.Removehydraulicreservoircap.
4.Locatethefronthydraulichoseunderthehydraulic tankandplacedrainpanunderthetank(Figure73).
5.Loosenthehoseclampandmoveitdownthehose.
6.Removethefronthydraulichoseandallowtheuid torunoutofthetank.
Figure73
1.Hydraulictank3.Fronthydraulichose
2.Hydrauliclter
•Usecardboardorpapertondhydraulic leaks.
•Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
•Makesureallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
ReplacingtheHydraulicFluid
ServiceInterval:Every250hours—Changethe
hydrauliclterandhydraulicoilwhen usingMobil
®
1oil.
Every500hours—Changethe hydrauliclterandhydraulicoil whenusingToro
®
HYPR-OIL
hydraulicoil.
WARNING
Hothydraulicuidcancausesevereburns.
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.
™
500
Donotoverll.
Allowthehydraulicuidtocoolbeforeperforming anymaintenancetothehydraulicsystem.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
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ReplacingtheHydraulicFilter
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
Figure74).
(
Figure74
1.Hydraulictank
2.Hydrauliclter
Figure75
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.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengineandwaitforallmovingpartstostop beforeleavingtheoperatingposition.
3.Raisetherearofthemachineupontojackstands highenoughtoraisethedrivewheelsofftheground.
4.Starttheengineandmovethethrottlecontroltoidle position.
Ifthedrivewheeldoesnotrotate,itispossibleto assistthepurgingofthesystembycarefullyrotating thetireintheforwarddirection.
4.Removetheoldlterandwipethelteradapter gasketsurfaceclean(
Figure75).
5.Applyathincoathydraulicuidtotherubbergasket onthereplacementlter.
6.Installreplacementhydrauliclterontothelter adapter.Turntheoillterclockwiseuntiltherubber gasketcontactsthelteradapter,thentightenthe lteranadditional1/2turn(
Figure75).
5.Checkthehydraulicuidlevelasitdropsadduid asrequiredtomaintaintheproperlevel.
6.Repeatthisprocedurefortheoppositewheel.
7.Thoroughlycleantheareaaroundeachofthecharge pumphousings.
CheckingtheHydraulicLines
ServiceInterval:Every100hours
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Checkhydraulichosesandhosesforleaks,loosettings, kinkedhoses,loosemountingsupports,wear,weather andchemicaldeterioration.Makenecessaryrepairs beforeoperating.
MowerDeck Maintenance
Note:Keepareasaroundhydraulicsystemcleanfrom grassanddebrisbuildup.
WARNING
Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.
•Ifhydraulicuidisinjectedintotheskinit mustbesurgicallyremovedwithinafewhours byadoctorfamiliarwiththistypeofinjury. Gangrenemayresultifthisisnotdone.
•Keepbodyandhandsawayfrompinholeleaks ornozzlesthatejecthighpressurehydraulic uid.
•Usecardboardorpapertondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.
•Makesureallhydraulicuidhosesandhosesare ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto hydraulicsystem.
ServicingtheCuttingBlades
Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
WARNING
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator’s orbystander’sarea,resultinginseriouspersonal injuryordeath.
•Inspectthebladesperiodicallyforwearor damage.
•Replaceawornordamagedblade.
BeforeInspectingorServicingthe Blades
Parkthemachineonalevelsurface,disengagetheblades andsettheparkingbrake.Turntheignitionkeytooff. Removethekeyanddisconnectthesparkplugwires fromthesparkplugs.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure76).Iftheedges arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
2.Inspecttheblades,especiallythecurvedarea.Ifyou noticeanycracks,wear,oraslotforminginthisarea immediatelyinstallanewblades(
Figure76
1.CuttingEdge3.Wear/slotForming
2.CurvedArea4.Crack
Figure76).
53
Page 54
CheckingforBentBlades
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward.Measurefromalevelsurfacetothe cuttingedge,positionA,oftheblades(Figure77 ).Notethisdimension.
performanceandcontinuedsafetyconformanceof themachine,usegenuineT ororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
1.Holdthebladeendusingaragorthickly-padded glove.
2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(
Figure78).
Figure77
1.Measureherefromblade tohardsurface
2.PositionA
4.Rotatetheoppositeendsofthebladesforward.
5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).If thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
•Alwaysreplacebentordamagedbladewith anewblade.
•Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
RemovingtheBlades
Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum
Figure78
1.SailAreaofBlade3.Curvedwasher
2.Blade4.BladeBolt
SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure79).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
Figure79
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer( horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly( procedureuntilthebladeisbalanced.
Figure80).Ifthebladestaysina
Figure78).Repeatthis
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Page 55
Figure80
1.Blade2.Balancer
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure81).
Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead
Figure81).T orquethebladeboltto85-110ft-lb
( (115-150N-m).
position.Disconnectthesparkplugwire(s)from thesparkplug(s).
3.Adjustthetirepressureinthereartiresto12-14psi (83-97kPa).
4.Checkthatthebladesandspindleshaftsarenot bent.RefertoCheckingforBentBlades.
5.Settheheight-of-cuttothe3inch(7.6cm)position. RefertoAdjustingtheHeight-Of-CutinOperation.
6.Performthestepsinthefollowingproceduresin order.
CheckingtheMowerDeckSide-to-Side Height
1.Adjustthereartirepressure.
2.Ensurethebladesarenotbent.RefertoChecking forBentBlades.
3.Positionthebladesside-to-side.MeasureatBand Clocationsfromalevelsurfacetothecuttingedge ofbladetips(
Figure82).
Figure81
1.SailAreaofBlade
2.Blade
3.SpringDisk
4.BladeBolt
5.ConeTowardsBoltHead
CorrectingtheMowerQuality ofCut
Ifonedeckbladecutslowerthantheother,correctas follows.
Note:Tireairpressureiscriticalintheseprocedures. Makesurethereartireshavecorrectpressure.
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating
Figure82
1.Measurefromalevel surface
2.MeasurebladeatpointsB andC
4.ThedifferencebetweenmeasurementsBandC shouldbenomorethan1/4inch(6mm).IIfitis notcorrect,proceedtoChangingtheMowerDeck Side-to-SideHeight.
ChangingtheMowerDeckSide-to-Side Height
Changingtheside-to-sideheightisdonebyadjusting thereartirepressureandU-platesonthesideofthe enginedeck.
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1.Changethereartirepressure.Dothistothe correspondingsidethatneedsadjustment.
2.LocatetheU-platesonthesideoftheenginedeck
Figure83).
(
3.LoosentheU-plateononesideandadjustitupor downtomakethedifferencebetweenmeasurements BandCnomorethana1/4inch(6mm)(Figure83).
4.ProceedtoCheckingtheMowerDeckFront-to-Rear Pitch.
1.MeasurebladeatpointsA andB
ChangingtheMowerDeck Front-to-RearPitch
Figure84
2.Measurefromalevel surface
Figure83
1.U-plate2.Nutsandbolts
CheckingtheMowerDeckFront-to-Rear Pitch
1.Adjustthetirepressureinthereartiresto specications.
2.Positiononebladefront-to-rear.MeasureatAand Blocationsfromalevelsurfacetothecuttingedge ofthebladetips(Figure84).
Changingthefront-to-rearpitchisdonebyadjustingthe frontheight-of-cutposts.
1.Place3piecesof2x4woodunderthemowerdeck asshowninFigure85.Standthe2x4’sonthe4inch part.
Figure85
1.2x4pieceofwoodundermowerdeck
3.Themowerbladeshouldbea1/4inch(6mm)lower infrontatAthanintherearatB.Rotatebladesand repeatforotherblades.Ifitisnotcorrect,proceed toChangingtheDeckFront-to-RearPitch.
2.Loosenboththefrontandrearnutsonthe adjustmentrods(Figure86).
3.Theweightofthemowerdeckmustberestingonall threeofthe2x4’s(
Figure86).Thebacklipofthe mowerdeckisbuilta1/4inch(6mm)lowerthanthe frontlipofthemowerdeck.
4.Tightenboththefrontandrearnuts.
56
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5.Checkthefront-to-rearpitchofthecuttingunit.
g013167
1
2
6.Ifthedimensionsarenotcorrect,adjustthefront andrearnutsoneithersidetogetthecorrect front-to-rearpitch(
Figure86).
Figure87
1.Measurefromalevel surface
2.MeasurebladeatpointA
4.Themeasurementshouldbe3inch(7.6cm).
5.Ifitdoesnotmeasurecorrectly,locatethe height-of-cutrodontherightsideofthemachine
Figure88).
(
Figure86
1.Adjustmentrods3.Frontnuts
2.Rearnuts
MatchingHeightofCut
1.Checkthereartirepressure.
2.Settheheight-of-cuttothe3inch(7.6cm)position. RefertoAdjustingtheHeight-Of-CutinOperation.
3.Withthemachineonlevelsurface,positiononeblade front-to-rear.MeasureatAandfromlevelsurfaceto thecuttingedgeofthebladetips(
Figure87).
6.Adjusttheadjustmentboltuntilthebladetipsmatch 3inches(7.6cm)(Figure88).
Figure88
1.Height-of-cutrod
2.Adjustmentbolt
ReplacingtheGrassDeector
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury. Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstalla coverplate,amulchplate,grassdeectororbagger.
57
Page 58
1.Removethelocknut,bolt,springandspacerholding
g012749
thedeectortothepivotbrackets(Figure89). Removedamagedorworngrassdeector.
Figure89
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring8.Jhookendofspring
5.Springinstalled
7.Lendofspring,place behinddeckedgebefore installingbolt
Cleaning
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.
2.Placespacerandspringontograssdeector.Place theLendofspringbehinddeckedge.
Note:MakesuretheLendofspringisinstalled behinddeckedgebeforeinstallingtheboltasshown inFigure89.
3.Installboltandnut.PlacetheJhookendofspring aroundgrassdeector(Figure89).
Important:Thegrassdeectormustbeable torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothefull downposition.
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Page 59
Storage
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(page45).
4.Servicetheaircleaner;refertoServicingtheAir CleanerinEngineMaintenance(page32).
hole.Nowusethestartertocranktheengineand distributetheoilinsidethecylinder.Installthespark plug(s).Donotinstallthewireonthesparkplug(s).
10.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamagedordefective.
11.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
12.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitinamemorableplace.Coverthemachineto protectitandkeepitclean.
5.Greasethemachine;refertoGreasingand Lubricationin
6.Changetheengineoil;refertoServicingtheEngine inEngineMaintenance(page32).
7.Checkthetirepressure;refertoCheckingtheTire PressureinDriveSystemMaintenance(page41).
8.Forlong-termstorage:
A.Addstabilizer/conditioneradditivetofuelinthe
tank.
B.Runenginetodistributeconditionedfuelthrough
thefuelsystem(5minutes).
C.Stopengine,allowtocoolanddrainthefuel
tank;refertoServicingtheFuelTankin FuelSystemMaintenance(page38),oroperate engineuntilitstops.
D.Restartengineandrununtilitstops.Repeat,on
Chokeuntilenginewillnotrestart.
E.Disposeoffuelproperly.Recycleasperlocal
codes.
Lubrication(page30).
Note:Donotstorestabilizer/conditioned gasolineover90days.
9.Removethesparkplug(s)andcheckits condition;refertoServicingtheSparkPlugin EngineMaintenance(page32).Withthespark plug(s)removedfromtheengine,pourtwo tablespoonsofengineoilintothesparkplug
59
Page 60
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.
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Page 61
Problem
PossibleCauseCorrectiveAction
Bladesdonotrotate.
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.Checkthebelttension.
2.Installdrivebeltandcheckadjusting shaftsandbeltguidesforcorrect position.
3.Installnewdeckbelt.
4.Installdeckpulleyandchecktheidler pulley,idlerarmandspringforcorrect positionandfunction.
6.Adjusttheclutchairgap.
8.ContactanAuthorizedServiceDealer.
9.ContactanAuthorizedServiceDealer.
61
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Schematics
HydraulicSchematic(Rev.A)
62
Page 63
ElectricalSchematic(Rev.A)
63
Page 64
TheToroTotalCoverageWarranty
ALimitedWarranty(seewarrantyperiodsbelow)
Landscape Contractor Equipment(LCE)
ConditionsandProductsCovered
TheToroCompanyanditsafliate,ToroWarrantyCompany,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheToroProductslistedbelowifdefectiveinmaterialsor workmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:
ProductsWarrantyPeriod
AllMowers
•Engine**
•Battery1year
•Attachments1year
Mid-SizeWalk-BehindMowers GrandStand
•Frame ZMaster
•Engine
•Frame
ZMaster
•Frame
*Whicheveroccursrst.
**SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer .Kawasaki
FXengineshavea3yearwarrantytermforresidentialuse.Residentialusemeansuseofthe
productonthesamelotasyourhome.
***LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atT oro’soption,underwarrantyatnocostforparts
andlabor .Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor
corrosionarenotcovered.
Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.
TM
Mowers5yearsor1,200hours*
®
Z400,Z500Mowers
®
G3Mowers5yearsor1,200hours*
2years
2years
Lifetime(originalowneronly)*** 4yearsor1,200hours* 2years** Lifetime(originalowneronly)***
Lifetime(originalowneronly)***
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,refertotheY ellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww.Toro.com.Y oumayalsocallthenumbers listedinitem#3tousethe24-hourToroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer.Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:
RLCCustomerCareDepartment ToroW arrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)
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.
•Pickupanddeliverycharges.
GeneralConditions
Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedToroServiceDealerusingToroapprovedreplacementparts.
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.
Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty
Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedToroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirToroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee information,contacttheToroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany.
374-0252RevA
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