Toro 74804TE Operator's Manual

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Form No. 3326–964 Rev A

Z350

Z-Master with 122cm Mower and Bagger

Model No. 74804TE—Serial No. 220000001 and Up

Operator ’s Manual

English (GB)

This spark ignition system complies with Canadian ICES-002.

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

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

Contents

Page

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

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

Safe Operation Practices for Ride-on (riding) Rotary

Lawnmower Machines 3. . . . . . . . . . . . . . . . . . . .

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

Toro Riding Mower Safety 5. . . . . . . . . . . . . . . . . . .

Sound Pressure Level 5. . . . . . . . . . . . . . . . . . . . . . .

Sound Power Level 5. . . . . . . . . . . . . . . . . . . . . . . .

Vibration Level 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Gasoline and Oil 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Gasoline 13. . . . . . . . . . . . . . . . . . . . .

Using Stabilizer/Conditioner 13. . . . . . . . . . . . . . . . .

Filling the Fuel Tank 13. . . . . . . . . . . . . . . . . . . . . . .

Check Engine Oil Level 13. . . . . . . . . . . . . . . . . . . . .

Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the bracket from Rear Tail Wheel 14. . . .

Removing the Deck Banding 14. . . . . . . . . . . . . . . . .

Checking the Tire Pressure 14. . . . . . . . . . . . . . . . . .

Activating the Battery 14. . . . . . . . . . . . . . . . . . . . . .

Removing the Machine from Crate 15. . . . . . . . . . . .

Checking the Hydraulic Fluid 15. . . . . . . . . . . . . . . .

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

Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Think Safety First 15. . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating the Parking Brake 16. . . . . . . . . . . . . . . . .

Starting and Stopping the Engine 16. . . . . . . . . . . . . .

Operating the Power Take Off (PTO) 17. . . . . . . . . .

The Safety Interlock System 17. . . . . . . . . . . . . . . . .

Driving Forward or Backward 18. . . . . . . . . . . . . . . .

Stopping the Machine 19. . . . . . . . . . . . . . . . . . . . . .

Positioning the Seat 19. . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Height-of-Cut 19. . . . . . . . . . . . . . . . .

Tilting the Mower 19. . . . . . . . . . . . . . . . . . . . . . . . . .

Dumping the Hopper 20. . . . . . . . . . . . . . . . . . . . . . .

 2001 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Page

Pushing the Machine by Hand 21. . . . . . . . . . . . . . . .

Removing the Deck and Carrier Frame 21. . . . . . . . .

Installing Deck and Carrier Frame 23. . . . . . . . . . . . .

Install the Mulching Baffle 25. . . . . . . . . . . . . . . . . .

Operating with Mulching Baffle 25. . . . . . . . . . . . . .

Installing the Bagger and Discharge Baffles 26. . . . .

Operating with Bagger 26. . . . . . . . . . . . . . . . . . . . . .

Installing and Removing the Plenum 27. . . . . . . . . . .

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

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

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

Correcting Cutting Unit Mismatch 31. . . . . . . . . . . .

Matching the Height–of–Cut 31. . . . . . . . . . . . . . . . .

Checking the Front-to-Rear Pitch 31. . . . . . . . . . . . .

Changing the Front-to-Rear Pitch 32. . . . . . . . . . . . .

Checking the Side-to-Side Level 32. . . . . . . . . . . . . .

Change the Side-to-Side Level 32. . . . . . . . . . . . . . .

Servicing the Air Cleaner 32. . . . . . . . . . . . . . . . . . . .

Servicing the Engine Oil 34. . . . . . . . . . . . . . . . . . . .

Servicing the Spark Plugs 35. . . . . . . . . . . . . . . . . . .

Servicing the Fuel Filter 36. . . . . . . . . . . . . . . . . . . . .

Servicing the Fuel Tank 37. . . . . . . . . . . . . . . . . . . . .

Cleaning the Cooling Systems 37. . . . . . . . . . . . . . . .

Greasing and Lubricating 38. . . . . . . . . . . . . . . . . . . .

Servicing the Gearbox Fluid 39. . . . . . . . . . . . . . . . .

Changing the Gearbox Fluid 39. . . . . . . . . . . . . . . . .

Checking the Gearbox Fluid 39. . . . . . . . . . . . . . . . .

Replacing the Castor Wheel Fork Bushings 39. . . . .

Replacing Idler Arm Bushings 40. . . . . . . . . . . . . . . .

Replacing Push Arm Bushings 41. . . . . . . . . . . . . . . .

Servicing the Castor Wheels and

Tail Wheel Bearings 42. . . . . . . . . . . . . . . . . . . . . .

Checking the Tire Pressure 42. . . . . . . . . . . . . . . . . .

Servicing the Hydraulic System 43. . . . . . . . . . . . . . .

Adjusting the Motion Controls 45. . . . . . . . . . . . . . . .

Replacing the Power Take Off (PTO) Belt 45. . . . . .

Replacing the Traction Belt 46. . . . . . . . . . . . . . . . . .

Replacing the Blower Belt 46. . . . . . . . . . . . . . . . . . .

Turning Engine Lift Hook 47. . . . . . . . . . . . . . . . . . .

Servicing the Fuse 47. . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Battery 47. . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Hopper Screens 50. . . . . . . . . . . . . . . . .

Cleaning the Hopper Full Sensor 50. . . . . . . . . . . . . .

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

Hydraulic Diagram 52. . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage 53. . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printed in the USA

Introduction

Safety

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

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

Figure 1

1. Location of the model and serial numbers

m–3220

Safe Operation Practices for Ride-on (riding) Rotary Lawnmower Machines

This machine meets or exceeds European Standards in effect at the time of production. However, improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert WARNING, or DANGER—“personal safety instruction.” Failure to comply with the instruction may result in personal injury or death.

symbol, which means CAUTION,

Safe Operating Practices

The following instructions are from the CEN standard EN 836:1997.

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

Training

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

Model No.

Serial No.

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

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

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

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

This manual uses two other words to highlight information.

Important calls attention to special mechanical

information and Note: emphasizes general information worthy of special attention.

• Read the instructions carefully. Be familiar with the

controls and the proper use of the equipment.

• Never allow children or people unfamiliar with these

instructions to use the lawnmower. Local regulations can restrict the age of the operator.

• Never mow while people, especially children, or pets

are nearby.

• Keep in mind that the operator or user is responsible for

accidents or hazards occurring to other people or their property.

• Do not carry passengers.

• All drivers should seek and obtain professional and

practical instruction. Such instruction should emphasize:

– the need for care and concentration when working

with ride-on machines;

– control of a ride-on machine sliding on a slope will

not be regained by the application of the brake. The main reasons for loss of control are:

• insufficient wheel grip;

• being driven too fast;

• inadequate braking;

• the type of machine is unsuitable for its task;

• lack of awareness of the effect of ground

conditions, especially slopes;

– do not stop or start suddenly when going up or

downhill;

• incorrect hitching and load distribution.

Preparation

• While mowing, always wear substantial footwear and

long trousers. Do not operate the equipment when barefoot or wearing open sandals.

• Thoroughly inspect the area where the equipment is to

be used and remove all objects which may be thrown by the machine.

• WARNING – Fuel is highly flammable.

– Store fuel in containers specifically designed for this

purpose.

– Refuel outdoors only and do not smoke while

refuelling.

– Add fuel before starting the engine. Never remove

the cap of the fuel tank or add fuel while the engine is running or when the engine is hot.

– If fuel is spilled, do not attempt to start the engine

but move the machine away from the area of spillage and avoid creating any source of ignition until fuel vapors have dissipated.

– Replace all fuel tanks and container caps securely.

• Replace faulty silencers.

• Before using, always visually inspect to see that the

blades, blade bolts and cutter assembly are not worn or damaged. Replace worn or damaged blades and bolts in sets to preserve balance.

• On multi-bladed machines, take care as rotating one

blade can cause other blades to rotate.

• engage clutch slowly, always keep machine

in gear, especially when travelling downhill;

– machine speeds should be kept low on slopes and

during tight turns;

– stay alert for humps and hollows and other hidden

hazards;

– never mow across the face of the slope, unless the

lawnmower is designed for this purpose.

• Use care when pulling loads or using heavy equipment.

– Use only approved drawbar hitch points. – Limit loads to those you can safely control. – Do not turn sharply. Use care when reversing. – Use counterweight(s) or wheel weights when

suggested in the instruction handbook.

• Watch out for traffic when crossing or near roadways.

• Stop the blades rotating before crossing surfaces other

than grass.

• When using any attachments, never direct discharge of

material toward bystanders nor allow anyone near the machine while in operation.

• Never operate the machine with defective guards or

without safety protective devices in place.

• Do not change the engine governor settings or

overspeed the engine. Operating the engine at excessive speed can increase the hazard of personal injury.

• Before leaving the operator’s position:

– disengage the power take-off and lower the

attachments;

Operation

• Do not operate the engine in a confined space where

dangerous carbon monoxide fumes can collect.

• Mow only in daylight or in good artificial light.

• Before attempting to start the engine, disengage all

blade attachment clutches and shift into neutral.

• Do not use on slopes of more than

–5 when mowing on side hills; –15 when mowing uphill; –10 when mowing downhill.

• Remember there is no such thing as a “safe” slope.

Travel on grass slopes requires particular care. To guard against overturning:

– change into neutral and set the parking brake; – stop the engine and remove the key.

• Disengage drive to attachments, stop the engine, and

disconnect the spark plug wire(s) or remove the ignition key

– before clearing blockages or unclogging chute; – before checking, cleaning or working on the

lawnmower;

– after striking a foreign object. Inspect the

lawnmower for damage and make repairs before restarting and operating the equipment;

– if the machine starts to vibrate abnormally (check

immediately).

• Disengage drive to attachments when transporting or

not in use.

• Stop the engine and disengage drive to attachment

– before refuelling; – before removing the grass catcher; – before making height adjustment unless adjustment

can be made from the operator’s position.

• Reduce the throttle setting during engine run-out and, if

the engine is provided with a shut-off valve, turn the fuel off at the conclusion of mowing.

Maintenance and Storage

• Keep all nuts, bolts and screws tight to be sure the

equipment is in safe working condition.

• Never store the equipment with fuel in the tank inside a

building where fumes can reach an open flame or spark.

• Allow the engine to cool before storing in any

enclosure.

• To reduce the fire hazard, keep the engine, silencer,

battery compartment and fuel storage area free of grass, leaves, or excessive grease.

• Check the grass catcher frequently for wear or

deterioration.

Sound Power Level

This unit has a sound power level of: 105 Lwa, based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments.

Vibration Level

This unit has a maximum hand-arm vibration level of

2.0 m/s2 and whole body vibration level of 1.2 m/s2, based on measurements of identical machines per EN 1033 and EN 1032.

• Replace worn or damaged parts for safety.

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

outdoors.

• On multi-bladed machines, take care as rotating one

blade can cause other blades to rotate.

• When machine is to be parked, stored or left

unattended, lower the cutting means unless a positive mechanical lock is used.

Toro Riding Mower Safety

The following list contains safety information specific to Toro products or other safety information that you must know that is not included in the CEN standard.

• Use only Toro-approved attachments. Warranty may be

voided if used with unapproved attachments.

Sound Pressure Level

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 90 dB(A), based on measurements of identical machines per procedures outlined in Directive 84/538/EEC and amendments.

Slope Chart

Safety and Instruction Decals

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

93-1265

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

93-6696

1. Stored energy hazard—read the

Operator’s Manual.

100-3613

1. Full body entanglement hazard—stay away from moving parts

100-3952

1. Hydraulic oil level

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

93-7010

1. Thrown object hazard—stay a safe distance from the machine.

2. Thrown object hazard, mower—keep the deflector in place.

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

1. Fast forward

2. Slow forward

3. Neutral

4. Slow reverse

98-1975

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

98-1977

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

98-1974

5. Fast reverse

6. Continuous variable setting

1. Warning—read the

2. Thrown object hazard—stay a safe distance from the machine.

3. Tipping hazard—do not drive the machine across a slope greater than 5 degrees, up a slope greater than 15 degrees, or down a slope greater than 10 degrees.

4. Crushing/dismemberment hazard of bystanders while backing—do not carry passengers and keep children a safe distance from the machine.

7. Speed/direction controls

98-4358

Operator’s Manual.

98-4363

1. Warning—torque the blade bolt/nut to 115–149 N⋅m (85–110ft.-lb.).

98-4369

1. Cutting/dismemberment hazard of hand or foot, mower blade—stay a safe distance from the machine.

98-4387

1. Warning—wear hearing protection.

104-0381

1. Height of cut in millimeters

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

1. Choke

2. Horn

3. Slow

4. Continuous variable setting

5. Fast

6. Power take-off (PTO)

1. Explosion hazard

2. No fire, open flames, or smoking.

3. Caustic liquid/chemical burn hazard

104-7808

7. Engine—stop

8. Engine—run

9. Engine—start

10. Engage the parking brake

11. Disengage the parking

104-4163

4. Wear eye protection

5. Read the

6. Keep bystanders a safe

brake.

Operator’s

Manual.

distance from the battery.

105-9350

1. Contains lead; do not discard.

2. Recycle

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

4. No sparks, flame, or smoking

5. Sulfuric acid can cause blindness or severe burns.

104-5091

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

7. Maximum fill line

8. Minimum fill line

9. Instructions for activating the battery

Gasoline and Oil

Warning

Recommended Gasoline

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

Important Never use methanol, gasoline containing

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

Danger

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

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

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

• Never fill the fuel tank inside an enclosed trailer.

• Do not fill the fuel tank completely full. Add

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

• Never smoke when handling gasoline, and stay

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

• Store gasoline in an approved container and

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

• Always place gasoline containers on the ground

away from your vehicle before filling.

• Do not fill gasoline containers inside a vehicle or

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

• When practical, remove gas–powered

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

• If this is not possible, then refuel such

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

• If a gasoline dispenser nozzle must be used, keep

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

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

• Avoid prolonged breathing of vapors.

• Keep your face away from the nozzle and gas

tank or conditioner opening.

• Keep gas away from eyes and skin.

Using Stabilizer/Conditioner

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

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

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

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system,

which causes hard starting

Important Do not use fuel additives containing

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

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

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

Filling the Fuel Tank

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

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

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

3. Install fuel tank cap securely. Wipe up any gasoline that

may have spilled.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking Oil Level, page 34.

Setup

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

Loose Parts

Note: Use the chart below to verify all parts have been shipped.

Description Qty. Use

Mulching baffle 1 For mulching mode Key 2 Use in the ignition Safety booklet

Operator’s manual Engine operator’s manual

Parts catalog 1 Registration card 1 Fill out and return to Toro.

Removing the bracket from Rear Tail Wheel

1. Remove locknut from bolt that fastens crate bracket to

tail wheel (Fig. 2).

2. Remove crate bracket from wheel bolt. Install locknut

on to bolt until fork clamps onto spacer (Fig. 2).

1 1 1

Read before operating the machine.

Checking the Tire Pressure

Check the air pressure in all tires; refer to Tire Pressure, page 42.

Activating the Battery

Bulk electrolyte with 1.265 specific gravity must be purchased from a local battery supply outlet.

Danger

Figure 2

1. Tail wheel

2. Fork

3. Bolt head

4. Washer

5. Locknut

6. Crate bracket

7. Spacer

8. Shim Washers

Removing the Deck Banding

4 5

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

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

m–5268

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

1. Remove the battery from the machine. Refer to

Removing the Battery on page 49.

2. Clean the top of the battery with a paper towel. Note: Never fill the battery with electrolyte while the

battery is installed in the machine. Electrolyte could be spilled on other parts and cause corrosion.

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

Remove any tie down banding that holds deck in place.

4. Slowly pour electrolyte into each battery cell until the level is up to the upper line (Fig. 3) on the battery case.

Important Do not overfill the battery because

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

5. Wait five to ten minutes after filling the battery cells. Add electrolyte, if necessary, until the electrolyte level is up to the upper line (Fig. 3) on the battery case.

6. Reinstall battery filler caps.

2 3

Checking the Hydraulic Fluid

Check the hydraulic fluid level before the engine is first started.

Refer to Checking the Hydraulic Fluid on page 43.

Check Engine Oil Level

Before you start the engine and use the machine, check the oil level in the engine crankcase; refer to Checking the Engine Oil Level, page 34.

Operation

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

1. Filler caps

2. Upper line

Figure 3

3. Lower line

m–5004

Warning

Charging battery produces gasses that can explode and cause serious injury.

• Keep cigarettes, sparks and flames away from

battery.

• Make sure the ignition switch is off.

• Ventilate when charging or using battery in an

enclosed space.

7. Charge the battery. Refer to Charging the Battery on

page 49.

8. Install the battery into the machine. Refer to Installing the Battery on page 48.

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

Think Safety First

Carefully read all the safety instructions and decals in the safety section. Knowing this information could help you, your family, pets or bystanders avoid injury.

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

Caution

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

Wear hearing protection when operating this machine.

Figure 4

1. Caution 2. Wear hearing protection

Removing the Machine from Crate

1. Tilt deck down and latch into position.

2. Machine can now be driven forward off crate.

Controls

Become familiar with all the controls before you start the engine and operate the machine (Fig. 5).

Releasing the Parking Brake

4 5

6 7

1. Motion control lever

2. Parking brake

3. Ignition switch

4. Throttle

5. Power take off (PTO)

Figure 5

6. Hourmeter

7. Choke

8. Drink holder

9. Fuel cap

10. Hydro reservoir cap

m–5287

1. Push in on the button and lower parking brake lever to

off (Fig. 7).

m–3287

Figure 7

1. Parking brake—Set

2. Button

3. Parking brake—Off

Starting and Stopping the Engine

Hour Meter

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

m–5270

Figure 6

1. Hour meter

Operating the Parking Brake

Always set the parking brake when you stop the machine or leave it unattended.

Setting the Parking Brake

1. Move the motion control levers to neutral (Fig. 5).

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

brake (Fig. 7). The parking brake lever should stay firmly in the set position.

Starting the Engine

1. Sit down on the seat and set the parking brake; refer to

Setting the Parking Brake, page 16.

2. Move the motion control levers to neutral.

3. Move the PTO (power take off) switch to off (Fig. 8).

4. Move the throttle control midway between slow and

fast positions before starting a cold engine.

5. Move the choke control to the on position before

starting a cold engine.

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

6. Turn ignition key to the start position to energize starter.

When engine starts, release key.

Note: If starter does not crank, move the motion control levers slightly forward or backward to locate neutral.

Important Do not engage starter for more than 10

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

7. After the engine starts, gradually move the choke to the

off position (Fig. 9). If the engine stalls or hesitates, move the choke back to the on position for a few seconds. Then move the throttle lever to desired setting. Repeat this as required.

Important Make sure fuel shut off valve is closed

before transporting or storing machine, as fuel leakage may occur.

Figure 8

1. PTO-Off

2. PTO-On

Figure 10

1. Fast

2. Slow

m–5269

Figure 9

1. Choke–On

2. Choke–Off

Figure 11

1. Off

2. Run

3. Start

m–2719

m–2718

Operating the Power Take Off (PTO)

The power take off (PTO) switch engages and disengages power to the attachment clutch (mower blades).

Engaging the Power Take Off (PTO)

1. With engine running, move motion control levers to

neutral to stop the machine.

2. To prevent engine stalling, from heavy load, move

throttle to the fast position.

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

to engage (Fig. 12).

m–5269

Figure 12

1. On-Engaged 2. Off-Disengaged

Stopping the Engine

1. Move the throttle lever to slow (Fig. 10).

2. Set the parking brake.

3. Turn the ignition key to off (Fig. 11).

Note: If the engine has been working hard or is hot, let it

idle for a minute before turning the ignition key off. This helps cool the engine before it is stopped. In an emergency, the engine may be stopped by turning the ignition key to off immediately.

4. Pull wire off spark plug(s) to prevent possibility of accidental starting before transporting or storing machine.

5. Close fuel shut off valve under fuel tank before transporting or storing machine.

Disengaging the Power Take Off (PTO)

1. Push the power take off (PTO) switch in. This moves

the switch to the off position to disengage (Fig. 12).

The Safety Interlock System

Caution

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

• Do not tamper with the interlock switches.

• Check the operation of the interlock switches

daily and replace any damaged switches before operating the machine.

Understanding the Safety Interlock System

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

• The parking brake is set.

• The power take off (PTO) is disengaged or off.

Driving Forward or Backward

The throttle control regulates the engine speed as measured in rpm (revolutions per minute). Place the throttle control in the fast position for best attachment performance. Always operate in the full throttle position when operating attachments.

• The motion control levers are in neutral position. The safety interlock system also is designed to stop the

engine when:

• The motion control levers are moved out of neutral with the parking brake is set.

• You rise from the seat when the power take off (PTO) is on or the motion control levers are not in neutral

• The motion control levers are moved out of neutral or PTO is engaged with the hopper tilted up

Testing the Safety Interlock System

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

1. Set the parking brake and move power take off (PTO)

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

2. Set the parking brake and move power take off (PTO)

to off. Move one then the other motion control lever forward or reverse. Try starting the engine; the engine should not crank.

Driving Forward

1. Release the parking brake; refer to Setting the Parking

Brake, page 16.

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

forward (Fig. 13).

Note: Engine will kill if motion control levers are moved with parking brake engaged.

To go straight, move both motion control levers the same distance (Fig. 13).

To turn move the motion control lever toward neutral, on the side you want to turn toward (Fig. 13).

The farther you move the motion control levers in either direction, the faster the machine will move in that direction.

To slow or stop move the motion control levers to neutral.

5 4 5

1 3

4 5

3. Set the parking brake, move power take off (PTO) to off

and hold the motion control levers in neutral. Now start the engine. While the engine is running engage the power take off (PTO) and rise slightly from the seat; the engine should stop.

4. Set the parking brake, move power take off (PTO) to off

and hold the motion control levers in neutral. Now start the engine. While the engine is running, move the motion control levers forward or reverse; the engine should stop.

5. Tilt the hopper up, set the parking brake, move power

take off (PTO) to off and hold the motion control levers in neutral. Now start the engine. While the engine is running, move the motion control levers forward or reverse; the engine should stop.

m–3288

Figure 13

1. Motion control lever-neutral position

2. Forward

3. Backward

4. Slow

5. Fast

Driving Backward

1. Release the parking brake; refer to Setting the Parking Brake, page 16.

2. To go backward, slowly pull the motion control levers rearward (Fig. 13).

To go straight, move both motion control levers the same distance (Fig. 13).

To turn move the motion control lever toward neutral, on the side you want to turn toward (Fig. 13).

To slow or stop move the motion control levers to neutral.

Stopping the Machine

To stop the machine, move the motion control levers to neutral, disengage the power take off (PTO), and turn the ignition key to off. Also set the parking brake when you leave the machine; refer to Setting the Parking Brake, page 16. Remember to remove the key from the ignition switch.

m–3280

Figure 15

1. Adjustment slot 2. Mounting bolt

Caution

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

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

Positioning the Seat

The seat can move forward and backward. Position the seat where you have the best control of the machine and are most comfortable.

1. To adjust, remove the locknut and washer, and tip seat

forward (Fig. 14).

Adjusting the Height-of-Cut

The height-of-cut can be adjusted from 1 to 4-1/2 inches (25 to 115 mm) in 1/2 inch (13 mm) increments by relocating four hairpin cotter pins in different hole locations.

Note: Fine adjustment can be done by removing washers.

1. To adjust, remove hairpin cotter from height-of-cut post

(Fig. 16).

2. Select hole in height-of-cut post corresponding to the

height-of-cut desired. Lift on side of deck to align holes and insert hairpin cotter (Fig. 16).

Important All four hairpin cotter pins must be in the

same hole location for a level cut.

m–3767

Figure 14

1. Locknut

2. Washer

2. Loosen the seat mounting bolts slide seat to the desired

position in the adjusting slots and tighten the mounting bolts (Fig. 15).

3. Lower seat and secure with washer and locknut

(Fig. 14).

3. Seat base

Figure 16

1. Carrier Frame

2. Hairpin Cotter

3. Height–of–Cut Post

4. Washers

Tilting the Mower

The mower can be tilted up for ease of service or to shorten unit length for transport and storage.

m–4856

Caution

The mower deck is heavy and could injure someone while raising or lowering the deck.

• Use caution when raising or or lowering deck.

Raising the Mower

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

brake, and turn the ignition key to off. Remove spark plug wire(s) and remove the key.

2. Lift on side of carrier frame near latch to release weight

on latch pin.

3. Pull out on latch pin to release and rotate into notch to

hold in the unlocked position (Fig. 17). Repeat on the other side.

4. Rotate latch pins into released position after deck has

been lowered onto rear rollers.

1. Parking brake

2. Latch pin

3. Unlocked Position

Figure 17

4. Locked Position

5. Deck Handle

6. Lift here – after lowering

m–4864

m–4863

Figure 18

1. Mower up

Lowering the Mower

1. Pull out latch pins and rotate into notch to hold in the unlocked position (Fig. 17).

2. Standing in front of the mower, pull front deck handle forward and lower mower (Fig. 18).

3. Rotate latch pins into released position and lift on side of carrier frame near latch pin until latch pin engages (Fig. 17). Repeat on the other side.

Dumping the Hopper

The hopper is equipped with a sensor that checks for a full condition. When the alarm buzzer sounds the PTO must be moved to the off position immediately and the hopper needs to be emptied.

Important The hopper is interlocked with the PTO and

the engine will stop if these steps are not followed before dumping the hopper or getting out of the seat.

1. Locate the traction unit so the hopper door is located where you want to dump the clippings.

2. Ensure that the power take off (PTO) switch is off, move the traction controls to neutral and set the parking brake.

5. Standing in front of the mower, lift up on deck handle

and push rearward on front to raise mower (Fig. 18).

6. Raise mower until it contacts stops and latch pins snap

into locked position.

3. Unhook the rear door latch (Fig. 19).

4. Unhook the front latch on hopper (Fig. 19).

5. Lift up on the hopper in the lower front and dump the

clippings (Fig. 19).

1. Rear Door latch

2. Front Hopper latch

Figure 19

3. Lift here

m–4861

1. By-pass valve

m–5282

Figure 20

6. Lower the hopper. Firmly secure the hopper door so it

latches and secure the front hopper latch (Fig. 19).

Important Front hopper latch must be secured to

prevent hopper from accidently tilting during transport. Ensure the hopper door latch is fully closed.

Pushing the Machine by Hand

Important Always push the machine by hand. Never

tow the machine because hydraulic damage may occur.

Pushing the Machine

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

ignition key to off.

2. Rotate pump by-pass valves counterclockwise 2 turns.

This allows hydraulic fluid to by-pass the pump enabling the wheels to turn freely (Fig. 20).

Important Rotate by-pass valve a maximum of 2 turns

so the valve does not come out of the body causing fluid to run out.

3. Release the parking brake.

4. Push the machine.

Operating the Machine

Removing the Deck and Carrier Frame

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

brake, and turn the ignition key to off. Remove the key.

2. Lifting slightly on the deck handles, remove hairpin

cotters from the height-of-cut posts and separate mower from carrier frame (Fig. 21).

m–4856

Figure 21

1. Height –of–cut post

2. Hairpin Cotter

3. Remove plenum from traction unit. Refer to Installing

and Removing the Plenum on page 27.

4. Raise seat, to gain access to plenum cable. Remove

washer and nut from plenum cable end (Fig. 22).

3. Carrier Frame

1. Turn the by-pass valves clockwise until they are tight.

Do not over tighten (Fig. 20).

Note: The machine will not drive unless by-pass valves are turned in completely.

10.Tilt carrier frame down.

11. Remove the two nuts and bolts that hold the bar for

rubber guard. The bar is under the motion control levers. Fold the rubber guard onto the footrest (Fig. 24).

2 6

m–4851

Figure 22

1. Bracket

2. Plenum Cable

3. Washer

4. Nut

5. Plenum

6. Plenum cable guide

7. Plenum Latches

8. Blower Housing

5. Tilt carrier frame into its upright position. Refer to

Tilting the Mower on page 19.

6. Place a block, approximately 4 inches high, under the

carrier frame. This will raise the frame vertically.

7. Check to see if tension has been removed from the

spring assemblies. If tension remains add blocks to raise carrier frame higher. If there is too much tension use a smaller block (Fig. 23).

8. Remove shoulder bolts (3/8 x 7/8 inch) and locknuts

(3/8 inch) securing spring end plate assemblies to carrier frame (Fig. 23).

m–4858

Figure 24

1. Bar

2. Rubber Guard

3. Nut

4. Machine Panel

5. Screw

12.Remove hairpin cotters and pivot pin assemblies from push arms at traction unit pivot brackets (Fig. 25).

Note: Save all hardware for use when installing mower. Items 3 and 4 are part of traction unit.

Figure 23

1. Spring Assembly

2. Shoulder Bolt, 3/8 x 7/8 inch

3. Locknut, 3/8 inch

9. Remove the block under the carrier frame.

m–3209

m–4870

Figure 25

1. Pivot Bracket

2. Push Arm

3. Pivot Pin Assembly–flat

4. Hairpin Cotter

Note: Drive shaft remains with traction unit.

13.Drive roll pin through hole in PTO drive shaft to

separate from gearbox shaft (Fig. 26).

M–4532

Figure 26

1. PTO Driveshaft

2. Universal Joint

3. Gearbox shaft

4. Roll Pin

14.Move deck and carrier frame away from traction unit.

Important Remove drive shaft from gearbox shaft if

you do not hook up a deck immediately or when putting on optional attachments.

1. Slide the driveshaft on gearbox shaft. Install 2 bolts

(3/8 x 1-5/8 inches) and locknuts (3/8 inch) in universal joint (Fig. 28).

Note: The gearbox shaft has a spline to correctly align gearbox and PTO drive shaft. Align the spline and slide the PTO drive shaft onto gearbox.

m–3198

Figure 28

1. PTO Driveshaft

2. Universal Joint

3. Gearbox shaft

4. Bolt, 3/8 x 1-5/8 inch

5. Locknut, 3/8 inch

15.Remove 2 bolts (3/8 x 1-5/8 inches) and locknuts

(3/8 inch) from universal joint and slide the driveshaft off gearbox shaft (Fig. 27).

Note: Save all hardware for use when installing mower.

m–3198

Figure 27

1. PTO Driveshaft

2. Universal Joint

3. Gearbox shaft

4. Bolt, 3/8 x 1-5/8 inches

5. Locknut, 3/8 inch

2. Position carrier frame in front of traction unit and place

push arms into clevises (Fig. 29).

3. Install push arms with pivot pin assemblies, aligned

with flat against frame, and secure with hairpin cotters (Fig. 29).

Note: Pivot pin assemblies and hairpin cotters are part of traction unit.

m–4870

Figure 29

1. Clevis

2. Push Arm

3. Pivot Pin Assembly–flat

4. Hairpin Cotter

Installing Deck and Carrier Frame

Note: Install drive shaft to gearbox shaft if it is not hooked up. Proceed to step 2 if the driveshaft is hooked up.

4. Tilt carrier frame into its upright position. Refer to

Tilting the Mower on page 19.

5. Place a block, approximately 4 inches high, under the carrier frame. This will raise the frame vertically.

6. Secure spring end plate assembly to carrier frame with a shoulder bolt (3/8 x 7/8 inch) and a locknut (3/8 inch) (Fig. 30).

m–4872

Figure 30

1. Spring Assembly

2. Shoulder Bolt, 3/8 x 7/8 inch

3. Locknut, 3/8 inch

Note: You may have to install spring to traction unit if it is not installed.

7. Install shoulder bolts (3/8 x 7/8 inch) and locknuts (3/8 inch) securing spring end plate assemblies to traction unit (Fig. 31).

M–4532

Figure 32

1. PTO Driveshaft

2. Universal Joint

3. Gearbox shaft

4. Roll Pin

11. Remove the 4 inch block. Release the latch levers and

push carrier frame down. Latch pins should lock.

12.Select hole in height–of–cut post corresponding to the

height-of-cut desired. Lift on side and front to align holes and hairpin cotter (Fig. 33).

m–3209

Figure 31

1. Spring Assembly

2. Shoulder Bolt, 3/8 x 7/8 inch

3. Locknut, 3/8 inch

8. Position mower in front of traction unit.

9. Rotate PTO drive shaft so holes align with hole in

gearbox shaft and slide together (Fig. 32).

10.Drive roll pin through hole to secure PTO drive shaft to gearbox shaft (Fig. 32).

m–4856

Figure 33

1. Carrier Frame

2. Hairpin Cotter

3. Height–of–Cut Post

Note: All four hairpin cotters should be in the same hole location for a level cut.

13.Tilt carrier frame into its upright position. Refer to

Tilting the Mower on page 19.

14.Route plenum cable under seat. Raise seat, to gain

access to plenum cable. Install cable into bracket and install washer and nut (Fig. 34).

2 6

4 5 72

m–4851

Figure 34

1. Bracket

2. Plenum Cable

3. Washer

4. Nut

5. Plenum

6. Plenum cable guide

7. Plenum Latches

8. Blower Housing

15.Install plenum to blower housing and wrap cable around

guide. Refer to Installing and Removing the Plenum on page 27.

1. Tilt mower into the vertical position, refer to; Tilting the

Mower, page 19.

2. Remove screws, washers, left and right bagger baffles

locknuts, carriage bolts, and left and right discharge baffles from the mower (Fig. 38).

Note: Reinstall all hardware into deck for use when reinstalling bagging baffles and safety.

3. Remove screws and washers that are installed into deck

for securing mulching baffle (Fig. 36).

4. Install baffle using hardware that was removed.

(Fig. 36).

Important All bagging and discharge baffles must be

removed when mulching (Fig. 38).

16.Install the rubber guard with bar, nuts and bolts under

the motion control levers. (Fig. 35).

m–4858

Figure 35

1. Bar

2. Rubber Guard

3. Nut

4. Machine Panel

5. Screw

Install the Mulching Baffle

Hardware to install mulching baffle is installed in deck.

m–527

Figure 36

1. Mulching baffle

2. Cap Screw

3. Retainer Nut (On top side of deck)

4. Washer

Operating with Mulching Baffle

When operating the mower with the mulching baffle installed, you must disengage the blower drive belt.

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Remove hairpin cotter and clevis pin from idler arm

(Fig. 37).

3. Pull up on the spring loaded idler arm, behind blower

on lefthand side of unit, to relax pressure on blower belt (Fig. 37).

4. Align hole in idler arm with slot in frame and insert

clevis pin. Secure with hairpin cotter to hold in position.

m–3548

Figure 37

1. Idler arm

2. Frame slot

3. Clevis pin

4. Hairpin cotter

5. When operating in mulching mode, the plenum can be

removed to prevent damage to it. Refer to Installing and Removing the Plenum on page 27.

Installing the Bagger and Discharge Baffles

When changing from mulching to bagging, baffles must be removed and replaced

1. Tilt mower into the vertical position, refer to Tilting the

Mower on page 19.

m–5272

Figure 38

1. Bagger baffle

2. Retainer Nut

3. Cap Screw

4. Discharge baffle

5. Carriage Bolt

6. Lock Nut

7. Washer

Operating with Bagger

When operating the mower with bagger baffles installed you must engage the blower drive belt.

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Ensure belt is around blower, idler and PTO pulleys.

2. Remove screws, washers and mulching baffle from the

mower (Fig. 36).

Note: Reinstall cap screws into deck for use when installing mulching baffle and safety.

3. Position the left and right front bagger baffles inside the

mower and secure with screws into the retainer nuts (Fig. 38).

4. Position the left and right rear discharge baffles inside

the mower. Secure with screws and washers through the bottom and carriage bolts inside of mower rear discharge. Secure carriage bolts with locknuts (Fig. 38).

Important All bagging baffles and discharge baffles

must be in place when bagging.

3. Push up on the spring loaded idler arm, behind blower

on lefthand side of unit, to relax pressure on clevis pin (Fig. 39).

4. Remove hairpin cotter and clevis pin from slot in frame

and allow idler down, to tension belt (Fig. 39).

5. Install hairpin cotter and clevis pin in outer hole of idler

arm for storage (Fig. 39).

4. Flip seat up and unlatch plenum from both sides of

blower inlet (Fig. 40).

5. Pull plenum out from blower housing and place it on

the ground (Fig. 40).

6. Pull or slide plenum out from between deck and traction

tire (Fig. 40).

m–3548

Figure 39

1. Idler arm

2. Frame slot

3. Clevis pin

4. Hairpin cotter

Installing and Removing the Plenum

To avoid damage to the plenum, remove the plenum when not in bagging mode.

Caution

Hands and fingers can be cut when removing bagging components.

• Keep hands and fingers out of blower housing.

• Do not operate in bagging mode without entire

bagging system in place.

• Stop engine before cleaning bagging system.

2 6

5 72

m–4851

Figure 40

1. Bracket

2. Plenum Cable

3. Washer

4. Nut

5. Plenum

6. Plenum cable guide

7. Plenum Latches

8. Blower Housing

Installing the Plenum

1. Tilt deck to upright position. Refer to Tilting the Mower

on page 19.

2. Slide plenum, with blower end in first, between deck

and traction tire.

Removing the Removal

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

brake, and turn the ignition key to off. Remove the key.

2. Tilt deck to upright position. Refer to Tilting the Mower

on page 19.

3. Reach through from lefthand side in front of traction

tire, lift plenum and unwind cable clockwise around plenum cable guide.

3. Flip seat up, reach down and direct plenum into blower

housing. Ensure the plenum latches lock into both sides of blower housing (Fig. 40).

4. Reach through from lefthand side in front of traction

tire, lift plenum and wind cable counter clockwise around plenum cable guide (Fig. 40).

Maintenance

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

Recommended Maintenance Schedule

Maintenance Service

Interval

After first use

Each use

Every 5 hours

Every 25 hours

Every 50 hours

Maintenance Procedure

• Check the hydraulic fluid level.

• Change the oil.

• Change the hydraulic filter.

• Check the oil level.

• Check the safety system.

• Clean the hopper.

• Clean the mower housing.

• Clean the cooling systems.

• Check the hydraulic fluid level.

• Check the cutting blades.

• Grease the chassis.

• Grease the drive shaft.

• Grease the push arm bearings.

• Grease the PTO idler.

• Check the battery electrolyte.

• Grease the castor wheels.

• Service the foam air cleaner.

• Check the belts for wear/cracks.

• Check the tire pressure.

After first 100 hours • Change the mower gearbox oil.

• Change the engine oil.

• Check the mower gearbox oil.

Every 100 hours

Every 200 hours

Every 600 hours • Replace the safety air cleaner.

Before storage

• Check the primary air cleaner.

• Check the hydraulic lines.

• Change the mower gearbox oil (after initial 100 hours).

• Clean the cooling systems.

• Change the oil filter.

• Change the hydraulic filter.

• Check the spark plug(s).

• Replace the fuel filter.

• Change the mower gearbox oil.

• Perform all maintenance procedures listed above before storage

• Drain the gasoline.

• Charge the battery and disconnect the cables.

• Paint chipped surfaces.

More often in dusty, dirty conditions

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

Caution

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

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

Servicing the Cutting Blades

To ensure a superior quality of cut, keep the blades sharp. For convenient sharpening and replacement, you may want to keep extra blades on hand.

Danger

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

• Inspect the blade periodically for wear or

damage.

• Replace a worn or damaged blade.

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

Important Always check gearbox output shafts for

straightness after impacting solid objects with blades. Severe damage could result if gearbox is operated with bent output shafts

Inspecting the Blades

1. Inspect the cutting edges (Fig 41). If the edges are not

sharp or have nicks, remove and sharpen the blades. Refer to Sharpening the Blades on page 31.

2. Inspect the blades, especially the curved area (Fig. 41).

If you notice any damage, wear, or a slot forming in this area (item 3 in Fig. 41), immediately install a new blade.

m–151

1. Cutting Edge

2. Curved Area

Figure 41

3. Wear/slot Forming

Before Inspecting or Servicing the Blades

Park the machine on a level surface, disengage the blade control (PTO) and set the parking brake. Turn the ignition key to off. Remove the key and disconnect the spark plug wire(s) from the spark plug(s).

Checking for Bent Blades

1. Rotate the blades until the ends face forward and

backward (Fig. 42). Measure from a level surface to the cutting edge tip of the blades (Fig. 42). Note this dimension.

2. Rotate the opposite ends of the blades forward. Measure

from a level surface to the cutting edge tip of the blades at the same position as in step 1 above. The difference between the dimensions obtained in steps 1 and 2 must not exceed 3 mm (1/8 inch). If this dimension exceeds

3 mm (1/8 inch), the blade is bent and must be replaced. Refer to Removing the Blades, and Installing the Blades on page 30.

Front

M–4852

Figure 43

1. Cutting edge

Note: Use anti-seize lubricant on spindle and keyway before installing blade retainer.

1. Install the key in the retainer and install blade retainer

to spindle (Fig. 44).

M–4852

Figure 42

Warning

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

• Always replace a bent or damaged blade with a

new blade.

• Never file or create sharp notches in the edges

or surfaces of the blade.

Removing the Blades

Hold the blade end using a rag or thickly-padded glove. Remove the retainer bolt with its washer and spacer, and the shear bolts and locknuts from the blade retainer (Fig. 44).

Installing the Blades

Important The blades are different for each side and

rotate in opposite directions forcing clippings to the center rear of the mower. Align cutting edges properly when installing. Sails of blades must point towards the top of the deck.

2. Install the blade, spacer, washer, and retainer bolt to

spindle (Fig. 44).

3. Torque the retainer bolt to 115–140 Nm

(85–110 ft.-lb.).

Important Blade should spin after blade bolt is

torqued. If not, check to make sure the spacer is installed correctly.

4. Position the blade onto the blade retainer and secure

with shear bolts and locknuts (Fig. 44).

Important The curved part of the blade, the sail, must

be pointing upward toward the top of the mower to ensure proper cutting.

5. Torque blade shear bolts to 10.2 Nm (90 in.-lb.).

M–4458

Figure 44

1. Spindle

2. Key

3. Blade retainer

4. Blade

5. Sail Area of Blade

6. Retainer bolt

7. Spacer

8. Washer

9. Shear Bolt

10. Locknut

Sharpening the Blades

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

blade (Fig. 45). Maintain the original angle. The blade retains its balance if the same amount of material is removed from both cutting edges.

1. Check the tire pressure on both deck and traction unit.

2. Set the height-of-cut to the 2-1/2 inches (63 mm)

position following the height-of-cut decal.

3. With the machine on level surface, position one blade front-to-rear (Fig. 47). Measure at A from level surface to the cutting edge of the blade tips (Fig. 48).

m–1854

Figure 45

1. Sharpen at original angle

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

balancer (Fig. 46). If the blade stays in a horizontal position, the blade is balanced and can be used. If the blade is not balanced, file some metal off the end of the sail area only (Fig. 46). Repeat this procedure until the blade is balanced.

Figure 46

1. Blade 2. Balancer

m–1855

4. The measurement should be 2-1/2 inches (63 mm).

Rotate blades and repeat for opposite blade.

Front

Figure 47

MEASURE FROM

CUTTING EDGE TO A

LEVEL SURFACE

Figure 48

M–4852

Correcting Cutting Unit Mismatch

If one deck blade cuts lower than the other, correct as follows:

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Adjust the tire pressure in all tires to specifications and

check that the blades and spindle shafts are not bent. Refer to Checking for Bent Blades on page 29.

3. Set the height-of-cut to the 63 mm (2-1/2 inches)

position. Refer to Adjusting the Height-Of-Cut in the Operation section. Make sure there is no excessive wear on push arm pivot points.

4. Refer to Matching Height–of–Cut, Checking Front to

Rear Pitch and Checking Side to Side Leveling on pages 31, 31 and 32.

Matching the Height–of–Cut

The height of cut needs to be checked and correct before the front to rear pitch and side to side leveling is performed.

5. If it does not measure correctly remove or add washers

to the height–of–cut posts. Match the hole in the post with the decal and the measured height–of–cut (Fig. 33).

Note: Make sure you add or remove washers from all four height–of–cut posts.

Checking the Front-to-Rear Pitch

The height of cut needs to be checked and correct before the front to rear pitch leveling is performed.

1. Check the tire pressure on both deck and traction unit.

2. Position one blade front-to-rear (Fig. 49). Measure at C

and D locations (Fig. 49) from a level surface to the cutting edge of the blade tips (Fig. 50).

3. The mower blade should be 6–9.5 mm (1/4–3/8 inch) lower in front C than in the rear D. Rotate blades and

repeat for opposite blade. If it is not correct proceed to Change the Front–to–Rear Pitch.

Front

M–4852

Figure 49

MEASURE FROM TIP

OF CUTTING EDGE

TO A LEVEL SUR-

FACE

M–4852

Figure 50

Changing the Front-to-Rear Pitch

Changing the front–to–rear pitch is done by removing or adding washers to height of cut posts.

1. Check the tire pressure on both deck and traction unit.

2. To change the front-to-rear pitch, remove the hairpin

cotter and move an equal number of washers on front or rear height–of–cut posts.

3. Add washers to the height–of–cut posts to raise the

mower.

4. Remove washers from the height–of–cut posts to lower

the mower.

5. Check the Front–to–Rear Pitch.

M–4852

Figure 51

MEASURE FROM TIP

OF CUTTING EDGE

TO A LEVEL SUR-

FACE

M–4852

Figure 52

Change the Side-to-Side Level

Changing the side–to–side leveling is done by removing or adding washers to height of cut posts. Do this to the corresponding side that needs adjustment.

1. Check the tire pressure on both deck and traction unit.

2. To change the side-to-side leveling, remove the hairpin

cotter and remove or add washers on one side only.

3. Add washers to the height–of–cut posts to raise the

corresponding side of the mower.

4. Remove washers from the height–of–cut posts to lower

the corresponding side of the mower.

5. Recheck the front-to-rear pitch and side to side leveling

of the cutting unit.

Checking the Side-to-Side Level

The height of cut needs to be checked and correct before the side to side leveling is performed.

1. Check the tire pressure on both deck and traction unit.

2. Position the blades side-to-side (Fig. 51). Measure at A

and B locations (Fig. 51) from a level surface to the cutting edge of blade tips (Fig. 52).

3. The difference between measurements A and B should

be no more than 6 mm (1/4 inch).

Servicing the Air Cleaner

Primary Filter: Clean or replace every 200 operating hours or when Filter Minder reaches “Change Filter” level.

Safety Filter: Replace after every 600 operating hours. Note: Service the air cleaner more frequently if operating

conditions are extremely dusty or sandy.

Using the Filter Minder

This machine contains an air cleaner Filter Minder gauge. Filter Minder: Check this daily.

The plunger inside the gauge canister will change to red when the air cleaner element becomes dirty and restricted. When it changes red, air cleaner maintenance is required.

1. Start by visually checking the condition of the primary

element. If the element is visually dirty, replace the primary element. Do not attempt to clean it.

2. Reset the gauge by depressing the button in the bottom

of the canister until the plunger returns to the lowest point (Fig. 53).

3. Test run the engine and recheck the gauge. If the

plunger remains in the lowest range, normal operation can resume. If the plunger returns to the “Change Filter” level, the primary element is restricted and must be replaced, even though it may not appear to be dirty.

4. The gauge may be reset at any time, however it will

return to the prior position if corrective filter servicing has not been performed.

M–4824

Figure 53

1. Filter minder 2. Button (push to reset)

32 m–4845

Figure 54

1. Filter guard

2. Wing nut

3. Bolt

4. Filter

3. Release the latches on the air cleaner and pull the air cleaner cover off of the air cleaner body (Fig. 55).

4. Clean the inside of the air cleaner cover with compressed air.

5. Gently slide the primary filter out of the air cleaner body (Fig. 55). Avoid knocking the filter into the side of the body. Do not remove the safety filter, unless you intend to replace it as well.

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

Important Never attempt to clean the safety filter. If

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

Removing the Filter

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

brake, and turn the ignition key to off. Remove the key.

2. Remove the wing nut from the bolt in the air filter

guard. Rotate guard to gain access to filter (Fig. 54).

m–4387

1. Latches

2. Air cleaner cover

3. Air filter body

Figure 55

4. Primary filter

5. Safety filter

Cleaning the Primary Filter

Blow compressed air from the inside to the outside of the primary filter.

Important Do not exceed 685.5 kPa (100 psi) and keep

the hose at least 5 cm (2 inches) from the filter.

Installing the Filters

USE THESE SAE VISCOSITY OILS

10W–30

5W–20, 5W–30

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

damage. Do not use a damaged filter.

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

into the filter body (Fig. 55).

3. Carefully slide the primary filter over the safety filter

(Fig. 55). Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

Important Do not press on the soft inside area of the

filter.

4. Install the air cleaner cover with the side indicated as

UP facing up and secure the latches (Fig. 55).

Servicing the Engine Oil

Change oil:

• After the first 8 operating hours.

• After every 100 operating hours.

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

Oil Type: Detergent oil (API service SG or SH)

–20 0 20

–305–20 –10

40 60

01020

80 100

30 40

Checking the Engine Oil Level

1. Park the machine on a level surface, disengage the

power take off (PTO) and turn the ignition key to off. Remove the key.

2. Clean around the oil dipstick (Fig. 56) so dirt cannot

fall into the filler hole and damage the engine.

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

(Fig. 56).

4. Slide the oil dipstick fully into the filler tube (Fig. 56).

Pull the dipstick out and look at the metal end. If oil level is low, slowly pour only enough oil into the filler tube to raise the level to the full mark.

Important Do not overfill the crankcase with oil

because the engine may be damaged.

Crankcase Capacity: w/filter, 2.0 l (67.5 oz.) Viscosity: See table below

1. Oil dipstick

2. Filler Cap

m–3219m–4853

Figure 56

3. Metal end

Changing the Engine Oil

Changing the Engine Oil Filter

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

the oil so it drains better.

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

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

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

cap (Fig. 57).

4. When oil has drained completely, install the drain cap. Note: Dispose of the used oil at a recycling center.

Replace the oil filter after first 8 hours of use. Replace the oil filter every 200 hours or every other oil

change. Note: Change oil filter more frequently when operating

conditions are extremely dusty or sandy.

1. Drain the oil from the engine; refer to Changing/Draining Oil, page 35.

2. Remove the old filter and wipe the filter adapter (Fig. 58) gasket surface.

3. Pour new oil of the proper type in through the center hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by filter material.

4. Apply a thin coat of new oil to the rubber gasket on the replacement filter (Fig. 58).

m–5278

Figure 57

1. Oil drain cap

5. Slowly pour approximately 80% of the specified oil, on

page 34, into the fill opening (Fig. 56). Now check the oil level; refer to Checking Oil Level, page 34. Slowly add additional oil to bring to full mark on dipstick.

m–1256

Figure 58

1. Oil filter

2. Gasket

3. Adapter

5. Install the replacement oil filter to the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 58).

6. Fill the crankcase with the proper type of new oil; refer to Changing/Draining Oil, page 35.

Servicing the Spark Plugs

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

Type: Champion Premium Gold 2071 (or equivalent) Air Gap: 0.030 inch (0.76 mm)

Removing the Spark Plugs

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

brake, and turn the ignition key to off. Remove the key.

2. Pull the wire(s) off the spark plug(s) (Fig. 59). Now

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

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

m–5278

Figure 59

1. Spark plug wire 2. Spark plug

Checking the Spark Plugs

1. Look at the center of the spark plug(s) (Fig. 60). If you

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

Important Never clean the spark plug(s). Always

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

2. Check the gap between the center and side electrodes

(Fig. 60). Bend the side electrode (Fig. 60) if the gap is not correct.

0.030 inch (0.76 mm)

m–3215

Figure 60

1. Center electrode insulator

2. Side electrode

3. Air gap (not to scale)

Installing the Spark Plug(s)

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

correctly.

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

3. Push the wire(s) onto the spark plug(s) (Fig. 59).

Servicing the Fuel Filter

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

Replacing the Fuel Filter

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

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

brake, and turn the ignition key to off. Remove the key.

2. Close fuel shut–off valve at fuel tank (Fig. 62).

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

them away from the filter (Fig. 61).

4. Remove the filter from the fuel lines.

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

the filter.

6. Open fuel shut-off valve at fuel tank (Fig. 62).

Important Ensure that the fuel line is routed correctly

to avoid damage to the fuel line.

m–4853

Figure 61

1. Filter 2. Hose clamp

Servicing the Fuel Tank

Draining The Fuel Tank

Danger

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

• Drain gasoline from the fuel tank when the

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

• Never smoke when draining gasoline, and stay

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

1. Fuel shut-off valve

2. Hose clamp

Figure 62

3. Fuel line

4. Fuel cap

m–3293

Cleaning the Cooling Systems

Cleaning the Engine Screen

Before each use, check and clean engine screen. Remove any build–up of grass, dirt or other debris from the oil cooler screen and engine air intake (Fig. 63).

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

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

2. Close fuel shut–off valve at fuel tank (Fig. 62).

3. Loosen the hose clamp and slide it up the fuel line away

from the fuel shut-off valve (Fig. 62).

4. Pull the fuel line off fuel shut-off valve (Fig. 62). Open

fuel shut-off valve and allow gasoline to drain into a gas can or drain pan.

Note: Now is the best time to install a new fuel filter because the fuel tank is empty.

5. Install the fuel line onto the fuel shut-off valve. Slide

the hose clamp close to the fuel shut-off valve to secure the fuel line (Fig. 62).

Figure 63

1. Engine screen

Cleaning the Engine Fins

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

1. Remove the panels from the engine shroud.

2. Clean the engine cooling fins.

3. Install the panels onto the engine shroud.

m–5766

Figure 64

1. Panel

2. Engine shroud

3. Screws

Greasing and Lubricating

The unit must be lubricated regularly. Refer to the Recommended Maintenance Schedule on page 28.

Grease Type: No. 2 general purpose lithium base or molybdenum base grease.

How to Grease

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

ignition key to off. Remove the key.

2. Clean the grease fittings with a rag. Make sure to scrape

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

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

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

m–3289

m–5283

Figure 65

2. Grease the fittings on drive shaft and universal joints

(Fig. 66).

m–3203

Figure 66

1. PTO Driveshaft 2. Universal Joint

3. Grease the fittings on push arms (Fig. 67).

4. Wipe up any excess grease.

Where to Add Grease

1. Lubricate the castor wheel bearings and motion control

lever pivot until grease begins to ooze out of the bearings (Fig. 65).

m–4871

Figure 67

1. Push arm grease fitting

4. Grease the fittings on the carrier frame castor hubs and

castor wheels (Fig. 68).

Figure 68

1. Carrier Frame Castor Hub Grease Fitting

2. Castor Wheel Grease Fitting

Servicing the Gearbox Fluid

Change fluid:

• after initial 100 operating hours.

• each year before storage.

Fluid T ype: 85W–140 Mobilube or equivalent fluid.

Important Do not mix fluids.

Gearbox Capacity: 5–1/2 oz. (129.6 ml) each box

16–1/2 oz. (488 ml) for all three boxes

Check fluid after every 100 operating hours.

m–4846

1. Gearbox

2. Top plug

Figure 69

3. Side plug

4. Bottom plug

m–4857

Checking the Gearbox Fluid

The gearbox fluid must be checked after every 100 operating hours. Check all three gearboxes.

1. Warm the fluid in gearbox. Run the mower deck for a

few minutes.

2. Tilt mower into the vertical position, refer to; Tilting the

Mower, page 19.

Changing the Gearbox Fluid

The gearbox fluid must be changed after first 100 operating hours. Change all three gearboxes.

Important Do not mix fluids. Use only specified fluid

on page 39.

1. Warm the fluid in gearbox. Run the mower deck for a

few minutes.

2. Tilt mower into the vertical position, refer to; Tilting the

Mower, page 19.

3. With deck raised, remove plug on the bottom side of the

gearbox. Let fluid fully drain into a pan. (Fig. 69).

4. Reinstall the bottom plug into the gearbox. Use pipe

thread sealant if needed (Fig. 69).

5. Remove the top plug to fill gearbox (Fig. 69).

6. Fill gearbox with 129.6 ml (5–1/2 oz.) of fluid.

7. Reinstall the top plug into the gearbox (Fig. 69).

8. Repeat for remaining gearboxes.

3. Remove plug on the side of the gearbox. The fluid level

must be up to side hole in gearbox (Fig. 69).

4. If needed, fill fluid into top hole until it runs out the

side hole in gearbox. It is full when it runs out the side hole (Fig. 69).

Important Do not mix fluids. Do not overfill

gearboxes.

5. Reinstall the top and side plugs into gearbox using pipe

sealant (Fig. 69).

6. Fill gearbox with fluid.

7. Repeat for remaining gearboxes.

Replacing the Castor Wheel Fork Bushings

The castor wheel forks are mounted in bushings pressed into the top and bottom of the carrier frame castor tubes. To check the bushings, move the castor forks back and forth and side-to-side. If a castor fork is loose, the bushings are worn and must be replaced.

1. Tilt mower into the vertical position, refer to; Tilting the

Mower, page 19.

2. Remove the cap, thrust washer and 1/2 inch spacer from

the top of the castor wheel fork (Fig. 70).

3. Pull the castor wheel fork out of the mounting tube,

leaving the 1 inch spacer and thrust washers on the fork. Remember the location of thrust washers on each fork to ensure correct installation, and to maintain a level deck.

8. Grease the fitting on the carrier frame castor hub using

No. 2 general purpose lithium base or molybdenum base grease.

1 2

m–4182

Figure 70

1. Cap

2. Washer

3. Spacer, 13 mm (1/2 inch) (New)

4. Spacer, 26 mm (1 inch)

5. Caster Wheel Fork

4. Insert a pin punch into the castor hub and carefully drive out the bushings (Fig. 71). Clean the inside of the mounting tube.

5. Grease the inside and outside of the new bushings. Use a hammer and flat plate to carefully drive the bushings into the castor hub (Fig. 71).

6. Inspect the castor wheel fork for wear and replace if necessary (Fig. 70).

7. Slide the castor wheel fork through the bushings in the castor hub. Replace the 1/2 inch spacer and thrust washer onto the fork and secure with the cap (Fig. 70).

Important The inside diameter of the bushings may

collapse slightly when installed. If the castor wheel fork does not slide into the new bushings, ream both bushings to an inside diameter of 28.6 mm (1.126 inches).

m–3282

Figure 71

1. Carrier Frame Castor Hub 2. Bushing

Replacing Idler Arm Bushings

There are idler arms for the blower belt, PTO belt and traction belt. All three idler arms have pressed in bushings. To check the bushings, move the idler arms side-to-side and examine for wear. If the idler arms are loose, the bushings are worn and must be replaced.

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

ignition key to off. Remove the key.

2. Remove tension on idler arms and remove belt from the

idler. See one of the following figures 72, 73 or 74 that shows the idler you are checking.

3. Inspect the idler pivot pin assembly for wear and

replace if necessary. To check the bushings, move the idler arms side-to-side and examine for wear.

4. If the idler arms are loose, the bushings are worn and

must be replaced. Remove the hardware securing the idler pivot arm to the mower.

5. Insert a pin punch into the idler arm and carefully drive

out the bushings (Figures 72, 73 or 74). Clean the inside of the idler arm.

6. Use a hammer and flat plate to carefully drive new

bushings into the idler arm (Figures 72, 73 or 74).

7. Install the idler arm back onto the machine. Note: Grease the PTO idler arm using No. 2 general

purpose lithium base or molybdenum base grease.

8. Install the belt back onto idler pulley.

1. Pump Idler Pulley

2. Idler arm

3. Bushing

4. Nut

5. Bolt

Figure 72

6. Washer

7. Spacer

8. Shoulder bolt

9. Spring

10. Traction Belt

9 5

m–5299

1. Blower Idler Pulley

2. Bushing

3. Spacer

4. Washer

Figure 74

5. Nut

6. Bolt

7. Blower Belt

8. Spring

m–5297

m–5298

1. PTO Idler and pulley

2. Bushing

3. Bolt

Figure 73

Replacing Push Arm Bushings

The push arms have pressed in bushings on the end mounted to the traction unit. To check the bushings, move the push arms side-to-side and examine for wear. If a push arm is loose, the bushings are worn and must be replaced.

1. Remove the mower: refer to Removing the Mower in

4. Nut

5. Spacer

6. Spring

the Installation section.

2. Inspect the pivot pin assembly for wear and replace if

necessary.

3. Remove the retaining ring and flat washer securing the

push arm to the mower (Fig. 75).

1. Pin

2. Push arm

Figure 75

3. Flat washer, 1-1/2 inches

4. Retaining ring

m–4871

4. Insert a pin punch into the push arm and carefully drive out the bushings (Fig. 76). Clean the inside of the push arm.

5. Use a hammer and flat plate to carefully drive new bushings into the end of push arm (Fig. 76).

6. Install the castor wheel into the castor fork and secure

with the wheel bolt and locknut. Tighten the locknut until the spanner bushing bottoms against the inside of the castor forks (Fig. 77).

7. Grease the fitting on the castor wheel.

6. Place push arm onto carrier frame pin and secure with a

flat washer (1-1/2 inches) and retaining ring (Fig. 75).

7. Grease the fitting on the push arm using No. 2 general purpose lithium base or molybdenum base grease.

m–3284

Figure 76

1. Push arm 2. Bushing

Servicing the Castor Wheels and Tail Wheel Bearings

The castor wheels and tail wheel rotate on a roller bearing supported by a spanner bushing. If the bearing is kept well lubricated, wear will be minimal. Failure to keep the bearing well lubricated will cause rapid wear. A wobbly castor wheel usually indicates a worn bearing.

1. Remove the locknut and wheel bolt holding the castor wheel to the castor fork (Fig. 77).

2. Remove the washer and bushing, then pull the spanner bushing and roller bearing out of the wheel hub (Fig. 77).

3. Remove the other bushing from the wheel hub and clean any grease and dirt from the wheel hub (Fig. 77).

m–3283

Figure 77

1. Locknut

2. Wheel Bolt

3. Washer

4. Bushing

5. Spanner Bushing

6. Roller Bearing

7. Grease fitting

Checking the Tire Pressure

Maintain the air pressure in the front and rear tires as specified. Uneven tire pressure can cause uneven cut. Check the pressure at the valve stem after every 50 operating hours or monthly, whichever occurs first (Fig. 78 and 79). Check the tires when they are cold to get the most accurate pressure reading.

Pressure: 83 kPa (12 psi) drive wheels

83 kPa (12 psi) tail wheel

345 kPa (45 psi) castor wheels

4. Inspect the roller bearing, bushings, spanner bushing and inside of the wheel hub for wear. Replace any defective or worn parts (Fig. 77).

5. To assemble, place one bushing into the wheel hub. Grease the roller bearing and spanner bushing and slide them into the wheel hub. Place the second bushing into the wheel hub (Fig. 77).

6. Recheck level while fluid is warm. Add fluid to raise

level to top of the baffle, if required.

Note: Fluid level should be to the top of the baffle when

fluid is warm (Fig. 80).

7. Install cap on filler neck.

m–1872

Figure 78

1. Drive Wheel and Tail Wheel Valve Stem

m–3281

Figure 79

1. Castor Wheel Valve Stem

Servicing the Hydraulic System

Checking the Hydraulic Fluid

Check the hydraulic fluid level before engine is first started and after every 8 operating hours.

Fluid Type: Mobil 1 15w–50 synthetic oil or equivalent synthetic oil.

Important Use only oils specified. Other fluids could

cause system damage. Total System Capacity: 2.8 l (96 oz.)

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

Figure 80

1. Cap

2. Baffle

3. Fluid level—full

Warning

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

• If hydraulic fluid is injected into the skin it must

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are

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

m–5279

2. Clean area around filler neck of hydraulic tank (Fig. 80).

3. Remove cap from filler neck. Look inside to check if there is fluid in the reservoir (Fig. 80).

4. If there is no fluid, add fluid to reservoir approximately a 6 mm (1/4 inches) below the top of baffle.

5. Run the machine 15 minutes to allow any air to purge out of the system and warm fluid.

Replacing the Hydraulic Filter

Change the hydraulic filter:

• After the first 8 operating hours

• After every 200 operating hours

1. Position machine on a level surface, stop the engine,

and remove key from ignition switch.

Important Do not substitute automotive oil filter or

severe hydraulic system damage may result.

2. Remove hydro cap and temporarily cover opening with

a plastic bag and rubber band to prevent all hydro fluid from draining out.

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

wipe the filter adapter gasket surface clean (Fig. 81).

1. Hydraulic filter

2. Gasket

Figure 82

m–1256

3. Adapter

m–5284

Figure 81

1. Hydraulic filter

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

replacement filter (Fig. 82).

5. Install replacement hydraulic filter onto the filter

adapter. Do not tighten.

6. Remove plastic bag from tank opening and allow filter

to fill with hydro fluid.

7. When fluid overflows filter turn the oil filter clockwise

until the rubber gasket contacts the filter adapter, then tighten the filter an additional 1/2 turn (Fig. 82).

8. Clean up any spilled fluid.

9. If there is no fluid, add fluid to reservoir approximately

a 6 mm (1/4 inch) below the top of baffle.

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

air from the system. Stop the engine and check for leaks. If one or both wheels will not drive, refer Bleeding Hydraulic System, page 44.

Bleeding the Hydraulic System

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

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

and support with jack stands.

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

on one side and spin the wheel by hand.

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

engaged until wheel drives smoothly. (minimum 2 minutes).

4. Check hydraulic fluid level as it drops and add as

required to maintain proper level.

5. Repeat procedure on opposite wheel.

Check the Hydraulic Lines

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

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

Warning

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

• If hydraulic fluid is injected into the skin it must

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

• Keep body and hands away from pin hole leaks

or nozzles that eject high pressure hydraulic fluid.

• Use cardboard or paper to find hydraulic leaks.

• Safely relieve all pressure in the hydraulic

system before performing any work on the hydraulic system.

• Make sure all hydraulic fluid hoses and lines are

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

1. Motion control lever

2. Forward stop

3. Pump control plate

Figure 83

4. Control rod

5. Jam nut

m–5285

Adjusting the Motion Controls

If motion control levers do not align, adjustment is required. Adjust each rod separately.

1. Loosen jam nuts on pump control rod (Fig. 83).

2. Push and firmly hold motion control lever against

forward stop (Fig. 83).

3. Rotate pump control rod until pump control plate is in

the full forward position (Fig. 83). Motion control lever will lift off forward stop.

Important Hold motion control lever firmly against

forward stop to determine when pump control reaches stop.

4. Rotate control rod 1 turn in reverse direction and

tighten jam nuts (Fig. 83).

Important Motion control lever must contact forward

stop before pump contacts internal stop or pump damage may occur.

5. If motion control levers do not line up in neutral,

identify control rod of handle closer to the seat. Rotate to lengthen this control rod a little. Tighten jam nuts.

Replacing the Power Take Off (PTO) Belt

Check power take off (PTO) belt for wear after every 50 hours of operation.

1. Remove the bumper and guard that protects the PTO

belt and pulleys (Fig. 84).

Figure 84

1. Bumper

2. Guard

3. Frame

m–4881

4. Nut

5. Bolt

2. Using a rag or thickly padded glove, hold spring loaded idler against belts and pull spring down to remove from idler stud (Fig. 85).

3. Lower idler to relax tension on PTO belt and remove belt from gear box pulley (Fig. 85).

4. Remove clutch stop mounting bolts and unplug clutch wire harness (Fig. 85). Remove belt over clutch.

Replacing the Traction Belt

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

1. Remove PTO belt; refer to Replacing Power Take Off

(PTO) Belt on page 45.

2. Push spring loaded idler down and remove traction belt

from the engine, fixed idler and hydro pump pulleys (Fig. 87). Remove belt over clutch.

3. Install new belt over clutch and around engine, fixed

idler and hydro pump pulleys (Fig. 87).

8 5

m–5286

Figure 85

1. Idler

2. Spring

3. Gear box pulley

4. PTO belt

5. Clutch stop

6. Bolt

7. Clutch

8. Clutch electrical connector

5. Install new PTO belt over clutch and route around

gearbox pulley and above spring loaded idler (Fig. 86).

6. Hold spring loaded idler against belts and pull spring

down to install on idler stud (Fig. 85).

7. Install clutch stop (Fig. 85). Tighten mounting bolts

securely.

8. Plug clutch wire into wire harness.

4. Push spring loaded idler down and align below traction

belt. Release pressure on spring loaded idler (Fig. 87).

5. Install PTO belt; refer to Replacing Power Take Off

(PTO) Belt.

m–3225

Figure 87

1. Traction belt

2. Engine pulley

3. Fixed idler pulley

4. Hydro pump pulley

5. Spring loaded idler

Replacing the Blower Belt

Squealing when the belt is rotating, blower slipping causing frequent clogging of chute and blower, frayed belt edges, burn marks and cracks are all signs of a worn blower belt. Replace the blower belt if any of these conditions are evident.

Figure 86

1. PTO belt

2. Clutch pulley

3. Gearbox pulley

4. Spring loaded idler

9. Install bumper and guard that protects PTO belt

(Fig. 84).

m–3225

1. Stop the engine, remove the key and disconnect the

spark plug wire(s) from the spark plug(s).

2. Push up on the spring loaded idler arm behind left hand

traction tire to relax pressure on blower belt (Fig. 88). Lock into frame slot.

3. Remove worn blower belt.

4. Install new blower belt around PTO gearbox and blower

pulleys. Then release spring loaded idler arm and place belt above idler pulley (Fig. 88).

5. Check that belt aligns with PTO box, blower and idler

pulleys (Fig. 88).

m–5280

Figure 88

1. Blower belt

2. PTO Gearbox pulley

3. Blower pulley

4. Idler pulley

Turning Engine Lift Hook

Turn the engine lift hook if the engine is to be lifted. The engine lift hook is positioned to allow clearance for the air cleaner hose.

1. Locate on engine the lift hook in figure 89.

2. Remove the lift hook from engine. Rotate lift hook 180

degrees and reinstall.

3. Use the engine lift hook.

4. Rotate lift hook 180 degrees and reinstall to its original

position.

Important Return lift hook to original position after

engine has been reinstalled.

Servicing the Fuse

Service Interval/Specification

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

Fuse: Main F1–30 amp, blade-type

Alternator F2–25 amp, blade-type Safety Interlock and Clutch F3–15 amp, blade-type

1. Remove dash panel screws to gain access to fuse holder

(Fig. 90).

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

(Fig. 90).

Important Do not install fuses of greater capacity as

call out above. It could cause electrical system damage.

3 2

m–5281

Figure 90

1. Main-30 amp

2. Alternator-25 amp

3. Safety interlock and clutch-15 Amp

4. Screw

Figure 89

1. Engine Lift Hook 2. Screws

M–4855

Servicing the Battery

Warning

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

handling.

Checking Electrolyte Level

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

2. Look at the side of the battery. The electrolyte must be up to the upper line (Fig. 91). Do not allow the electrolyte to get below the lower line (Fig. 91).

3. If the electrolyte is low, add the required amount of distilled water; refer to Adding Water to the Battery, page 49.

Installing the Battery

Warning

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

Figure 91

1. Filler caps

2. Upper line

3. Lower line

Danger

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

• Do not drink electrolyte and avoid contact with

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

• Fill the battery where clean water is always

available for flushing the skin.

• Follow all instructions and comply with all

safety messages on the electrolyte container.

m–5004

• When removing or installing the battery, do not

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

• Do not allow metal tools to short between the

battery terminals and metal parts of the machine.

1. Position battery in tray with terminal posts toward the

engine (Fig. 92).

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

(+) battery terminal.

3. Then install negative battery cable and ground wire to

the negative (–) battery terminal.

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

(1/4 inch), and 2 locknuts (1/4 inch) (Fig. 92).

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

battery post.

6. Position support rods in mounting holes (Fig. 92).

Secure battery with 2 support rods, a battery clamp and 2 wing nuts (1/4 inch). Tighten wing nuts so battery is held securely in position and will not slide. Do not

overtighten.

Important Route cables so they do not contact metal

edges, frame members, or tail wheel.

Adding Water to the Battery

The best time to add distilled water to the battery is just

before you operate the machine. This lets the water mix thoroughly with the electrolyte solution.

Figure 92

1. Battery tray

2. Terminal boot

3. Positive battery cable

4. Negative battery cable

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

Removing the Battery

6. Washer, 1/4 inch

7. Battery support rod

8. Battery clamp

9. Wing nut, 1/4 inch

m–4886

1. Remove the battery from the machine.

2. Clean the top of the battery with a paper towel. Note: Never fill the battery with distilled water while the

battery installed in the machine. Electrolyte could be spilled on other parts and cause corrosion.

3. Remove the vent caps from the battery (Fig. 91).

4. Slowly pour distilled water into each battery cell until

the level is up to the upper line (Fig. 91) on the battery case.

Important Do not overfill the battery because

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

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

Add distilled water, if necessary, until the electrolyte level is up to the upper line (Fig. 91) on the battery case.

6. Reinstall battery vent caps.

Charging the Battery

Warning

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

• Always Disconnect the negative (black) battery

cable before disconnecting the positive (red) cable.

• Always Reconnect the positive (red) battery

cable before reconnecting the negative (black) cable.

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

brake, and turn the ignition key to off. Remove the key.

2. First disconnect the negative battery cable and ground

wire from the negative (–) battery terminal (Fig. 92).

3. Slide the red terminal boot off the positive (red) battery

terminal. Then remove positive (red) battery cable (Fig. 92).

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

clamp and support rods (Fig. 92).

Warning

Charging the battery produces gasses that can explode.

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

Important Always keep the battery fully charged

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

1. Remove the battery from the chassis; refer to Removing

the Battery, page 49.

2. Check the electrolyte level; refer to Checking

Electrolyte Level, page 47.

3. Make sure the filler caps are installed in battery. Charge

battery for 10 to 15 minutes at 25 to 30 amps or 30 minutes at 4–6 amps.

4. When the battery is fully charged, unplug the charger

from the electrical outlet, then disconnect the charger leads from the battery posts (Fig. 93).

5. Remove the battery.

m–4970

Figure 93

1. Positive Battery Post

2. Negative Battery Post

3. Red (+) Charger Lead

4. Black (–) Charger Lead

5. Install the battery in the machine and connect the battery cables; refer to Installing the Battery on page 48.

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

Cleaning the Hopper Screens

For best clipping collection, maximum air flow through the hopper is required. To provide maximum air flow, the hopper screens must be kept clean.

1. To clean the hopper screens dump the hopper to remove grass clippings.

2. With the door open, remove the knobs at the upper front of the hopper and slide the screens out the rear of the hopper (Fig. 94).

Cleaning the Hopper Full Sensor

The hopper full sensor, inside the top right side of the hopper, detects a beam of light from the transmitter to the receiver. If the light beam is blocked the sensor buzzer sounds. If the lenses are covered with clippings or debris it may give false hopper full signals and needs to be cleaned.

Note: There are two different positions the hopper full sensors can be mounted. The lower position will signal the hopper full alarm earlier and prevent plugging of the chute and blower.

1. To clean the hopper full sensor dump the hopper to

remove grass clippings.

2. With the door open, wipe off the lenses of both the

transmitter and receiver with a soft cloth or paper towel (Fig. 95).

3. To test the hopper full sensor for proper operation turn

the ignition key and PTO switch to on, but do not start the engine. Place a piece of heavy cardboard in front of the transmitter to block the light beam (Fig. 95). The alarm buzzer should sound.

Note: Do not use your hand to test for proper sensor operation as the light beam may pass through or around your hand and not properly activate the sensor.

3. Clean the screen by brushing off with your hand, blowing with compressed air or spraying with a stream of water.

4. Replace the screens and secure with knobs (Fig. 94). Close and latch the hopper door.

m–3546

Figure 94

1. Knob 2. Screen

m–3549

Figure 95

1. Transmitter

2. Receiver

3. Wire

Note: Make sure the wire between receiver and transmitter is tight. It can collect debris and give a false hopper full signal.

Wiring Diagram

FUEL

SOLINIO

1 X

15A

(SEAT)

(IGNITION)

KEY SWITCH PN 88–9830

OFF NO CONNECTION

ON B I A AND X Y

START B I S

SW1

2 Y

RYW

VIO

HOPPER SW.

CLOSED WHEN

OPERATOR

PRESENT

HOUR METER

KEY SW

–+

TANRRED

PINK

VIOLET

VIO

WIRE COLOR CODES

BROWN

BLACK

BLUEBUGREEN

YELLOW

WHITE

ORANGE

GREY

SW3

(NEUTRAL)

CLOSED WHEN

TRACTION DRIVE

IS IN NEUTRAL

VIO R

SPARK PLUGSPARK PLUG

SW2

(NEUTRAL)

IGNITION

MODULES

25A

30A

3 4

CLOSED WHEN

TRACTION DRIVE

IS IN NEUTRAL

SOLINOID

SHIFT

STARTER

OIL

REG

VIO

(START RELAY)

START

MAG

OIL

SWITCH

SWITCH CLOSES

WITH OIL

PRESSURE

3 4

+–

B+

(KILL RELAY)

SHOWN IN

OFF POSITION

SW4

(PTO)

SW5

(BRAKE)

SHOWN WITH

PARK BRAKE

DISENGAGED

PTO

GN PK BK

CLUTCH

BAG SENSOR

BUZZER

GND

REAR

PUMP

Hydraulic Diagram

HYDRAULIC TANK

A C

FILTER

A C

FRONT

PUMP

RIGHT

MOTOR

LEFT

MOTOR

Cleaning and Storage

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

brake and turn the ignition key to off. Remove the key.

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

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

3. Clean any dirt and chaff from the mower, chute, blower

and hopper.

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

mower, chute, blower and hopper, then wash with a garden hose.

Important You can wash the machine with mild

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

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

the Cutting Blades on page 29.

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

Cleaner, page 32.

7. Grease the machine; refer to Greasing and Lubricating

page 38.

8. Change the crankcase oil; refer to Servicing the Engine

Oil, page 34.

9. Change the hydraulic fluid; refer to Servicing the

Hydraulic System, page 43.

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

to Servicing the Spark Plug, page 35. With the spark plug(s) removed from the engine, pour two tablespoons of engine oil into the spark plug hole. Now use the starter to crank the engine and distribute the oil inside the cylinder. Install the spark plug(s). Do not install the wire on the spark plug(s).

12.Check the condition of all belts.

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

Pressure, page 42.

14.Disconnect the negative battery cable. Clean the battery

and battery terminals. Check the electrolyte level and charge it fully; refer to Servicing the Battery on page 47. Leave the negative battery cable disconnected from the battery during storage.

Important The battery must be fully charged to prevent

it from freezing and being damaged at temperatures below 32°F (0°C). A fully charged battery can be stored one winter season without recharging.

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

replace any part that is damaged or defective.

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

available from your Authorized Service Dealer.

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

Remove the key from the ignition switch and keep it in a memorable place. Cover the machine to protect it and keep it clean.

10.For long-term storage (more than 90 days) add

stabilizer/conditioner additive to fuel in the tank. A. Run engine to distribute conditioned fuel through

the fuel system (5 minutes).

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

refer to Servicing the Fuel Tank, page 37.

C. Restart engine and run until it stops. Repeat, on

choke until engine will not restart.

D. Dispose of fuel properly. Recycle as per local codes.

Note: Do not store stabilizer/conditioned gasoline over 90 days.

Troubleshooting

neutral

PROBLEM POSSIBLE CAUSES CORRECTIVE ACTION

Starter does not crank

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

1. Power take off (PTO) is ENGAGED.

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

3. Motion control levers are not in

4. Battery is dead.

5. Electrical connections are corroded or loose.

6. Fuse is blown. 6. Replace fuse.

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

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

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

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

4. Spark plug wires is loose or disconnected.

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

1. Move power take off (PTO) to DISENGAGED.

3. Move motion control levers into

4. Charge the battery.

5. Check electrical connections for good contact.

Dealer.

element.

4. Install wires on spark plug.

5. Install new, correctly gapped spark plugs.

Engine loses power.

Engine overheats.

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

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

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

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

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

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

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

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

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

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

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

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

7. Contact Authorized Service Dealer.

4. Remove obstruction from cooling fins and air passages.

5. Install new, correctly gapped spark plugs.

7. Contact Authorized Service Dealer.

3. Remove obstruction from cooling fins and air passages.

PROBLEM CORRECTIVE ACTIONPOSSIBLE CAUSES

Abnormal vibration.

Machine does not drive.

1. Engine mounting bolts are loose.

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

3. Engine pulley is damaged. 3. Contact Authorized Service

1. Parking brake is on.

2. Traction belt is worn, loose or broken.

3. Traction belt is off pulley. 3. Contact Authorized Service

4. Hydro fluid level low. 4. Add hydro fluid to reservoir.

1. Tighten engine mounting bolts.

2. Tighten the appropriate pulley.

Dealer.

1. Move parking brake to off.

2. Contact Authorized Service Dealer.

Dealer.

Toro 74804TE Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual