How it Works
Toro
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74949
Operator's Manual
80 pgs30.56 Mb0
Operator's Manual [es]
88 pgs5.11 Mb0
Operator's Manual [fr]
88 pgs5.11 Mb0
Parts Catalogue
60 pgs2.19 Mb0
Reference Guide
4 pgs145.25 Kb0
Setup Instructions
16 pgs119.7 Mb0
Table of contents
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Toro 74949, 74950, 74952, 74959, 75932 Operator's Manual

...
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Page 1
FormNo.3424-609RevA
ZMaster
®
Commercial3000
SeriesRidingMower
with48in,52in,60in,or72inTURBOFORCE SideDischargeMower
®
Registeratwww.T oro.com. OriginalInstructions(EN)
*3424-609*A
Page 2
ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.
GrossHorsepower:Thegrossornethorsepower ofthisenginewaslaboratoryratedbytheengine manufacturerinaccordancewiththeSocietyof AutomotiveEngineers(SAE)J1940orJ2723.As conguredtomeetsafety,emission,andoperating requirements,theactualenginetorqueonthisclass ofmowerwillbesignicantlylower.
Pleaserefertotheenginemanufacturer’sinformation includedwiththemachine.
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Introduction
Thisrotary-blade,ridinglawnmowerisintendedtobe usedbyprofessional,hiredoperators.Itisdesigned primarilyforcuttinggrassonwell-maintainedlawnson residentialorcommercialproperties.Itisnotdesigned forcuttingbrushorforagriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Y ouareresponsiblefor operatingtheproductproperlyandsafely .
YoumaycontactT orodirectlyatwww.Exmark.com forproductsafetyandoperationtrainingmaterials, accessoryinformation,helpndingadealer,orto registeryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Important:Withyourmobiledevice,youcan
scantheQRcode(ifequipped)ontheserial numberdecaltoaccesswarranty,parts,andother productinformation.
©2018—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol
Contactusatwww.Toro.com.
2
g233771
PrintedintheUSA
AllRightsReserved
Page 3
(Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
Figure2
1.Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Contents
Safety.......................................................................4
GeneralSafety...................................................4
SlopeIndicator...................................................5
g000502
SafetyandInstructionalDecals..........................6
ProductOverview...................................................13
Controls...........................................................13
Specications..................................................15
BeforeOperation.................................................16
BeforeOperationSafety...................................16
AddingFuel......................................................17
PerformingDailyMaintenance..........................17
BreakinginaNewMachine..............................17
UsingtheRollover-ProtectionSystem
(ROPS).........................................................18
UsingtheSafety-InterlockSystem....................19
PositioningtheSeat..........................................20
UnlatchingtheSeat..........................................20
ChangingtheSeatSuspension.........................20
AdjustingtheMyRide™Suspension
System..........................................................21
DuringOperation.................................................22
DuringOperationSafety...................................22
EnteringtheOperator’sPosition.......................23
OperatingtheParkingBrake.............................24
OperatingtheMowerBlade-ControlSwitch
(PTO)............................................................24
OperatingtheThrottle.......................................24
OperatingtheChoke........................................25
StartingtheEngine...........................................25
ShuttingOfftheEngine.....................................26
UsingtheMotion-ControlLevers.......................26
DrivingtheMachine..........................................26
UsingtheSideDischarge.................................28
AdjustingtheHeightofCut...............................28
AdjustingtheAnti-ScalpRollers........................29
AdjustingtheFlowBafeCamLocks................30
PositioningtheFlowBafe................................30
OperatingTips.................................................31
AfterOperation....................................................32
AfterOperationSafety......................................32
UsingtheFuel-ShutoffValve.............................32
UsingtheDrive-Wheel-ReleaseValves............32
TransportingtheMachine.................................33
Maintenance...........................................................35
RecommendedMaintenanceSchedule(s)...........35
Pre-MaintenanceProcedures..............................36
MaintenanceSafety..........................................36
Lubrication..........................................................37
GreasingtheMachine.......................................37
AddingLightOilorSprayLubrication................37
GreasingtheMowerDeck................................37
LubricatingtheCaster-WheelHubs..................38
EngineMaintenance...........................................40
IdentifyingtheEngine.......................................40
EngineSafety...................................................40
ServicingaKawasaki
®
Engine..........................40
3
Page 4
ServicingaKohler
CheckingtheSparkArrester.............................51
FuelSystemMaintenance...................................51
ReplacingtheFuelFilter...................................51
ServicingtheFuelT ank.....................................51
ElectricalSystemMaintenance...........................52
ElectricalSystemSafety...................................52
ServicingtheBattery.........................................52
ServicingtheFuses..........................................54
DriveSystemMaintenance..................................54
CheckingtheSeatBelt.....................................54
CheckingtheRoll-BarKnobs............................54
AdjustingtheTracking......................................55
CheckingtheTirePressure...............................56
CheckingtheWheel-LugNuts..........................56
CheckingtheWheel-HubSlottedNut................56
AdjustingtheCaster-PivotBearing...................56
UsingtheClutchShim......................................57
CoolingSystemMaintenance..............................59
CleaningtheEngineScreenandEngine-Oil
Cooler...........................................................59
CleaningtheEngine-CoolingFinsand
Shrouds........................................................59
CheckingandCleaningtheHydraulic-Unit
Shrouds........................................................60
BrakeMaintenance.............................................60
AdjustingtheParkingBrake..............................60
BeltMaintenance................................................61
InspectingtheBelts..........................................61
ReplacingtheMowerBelt.................................61
ReplacingtheHydraulicPump-Drive
Belt................................................................62
ControlsSystemMaintenance.............................63
AdjustingtheControl-HandlePosition..............63
AdjustingtheMotion-ControlLinkage...............64
AdjustingtheMotion-ControlDamper...............65
AdjustingtheMotion-ControlNeutral-Lock
Pivot..............................................................65
HydraulicSystemMaintenance...........................66
HydraulicSystemSafety...................................66
ServicingtheHydraulicSystem........................66
MowerDeckMaintenance....................................68
LevelingtheMowerDeck..................................68
ServicingtheCuttingBlades.............................70
RemovingtheMowerDeck...............................71
ReplacingtheGrassDeector..........................72
Cleaning..............................................................73
CleaningundertheMowerDeck.......................73
CleaningtheSuspensionSystem.....................73
DisposingofWaste...........................................73
Storage...................................................................74
StorageSafety..................................................74
CleaningandStorage.......................................74
Troubleshooting......................................................75
Schematics.............................................................77
®
Engine...............................45
Safety
Thismachinehasbeendesignedinaccordancewith ANSIB71.4-2012.

GeneralSafety

Thisproductiscapableofamputatinghandsand feetandofthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriouspersonalinjury.
Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.
•Alwayskeeptherollbarinthefullyraisedand
lockedpositionandusetheseatbelt.
•Donotoperatethemachineneardrop-offs,
ditches,embankments,water,orotherhazards,or onslopesgreaterthan15degrees.
•Readandunderstandthecontentsofthis
Operator’sManualbeforestartingtheengine.
•Donotputyourhandsorfeetnearmoving
componentsofthemachine.
•Donotoperatethemachinewithoutallguards
andothersafetyprotectivedevicesinplaceand workingonthemachine.
•Keepchildrenandbystandersoutoftheoperating
area.Neverallowchildrentooperatethemachine.
•Stopthemachine,shutofftheengine,andremove
thekeybeforeservicing,fueling,orunclogging themachine.
Improperlyusingormaintainingthismachinecan resultininjury.T oreducethepotentialforinjury, complywiththesesafetyinstructionsandalways payattentiontothesafety-alertsymbol( meansCaution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.
Youcanndadditionalsafetyinformationwhere neededthroughoutthismanual.
),which
4
Page 5
SlopeIndicator
Figure3
Youmaycopythispageforpersonaluse.
1.Themaximumslopeyoucanoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslopeof hillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge
5
g011841
Page 6
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
BatterySymbols
Someorallofthesesymbolsareonyourbattery
decal93-7818
93-7818
decalbatterysymbols
1.Warning—readtheOperator'sManualforinstructionson torquingthebladebolt/nutto1 15to149N∙m(85to110 ft-lb).
1.Explosionhazard
6.Keepbystandersasafe distanceawayfromthe battery.
2.Nore,opename,or smoking
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.
3.Causticliquid/chemical burnhazard
8.Batteryacidcancause blindnessorsevereburns.
4.Weareyeprotection.9.Flusheyesimmediately withwaterandgetmedical helpfast.
5.ReadtheOperator's
Manual.
10.Containslead;donot discard
Manufacturer'sMark
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
decal99-8936
99-8936
1.Machinespeed4.Neutral
decaloemmarkt
2.Fast5.Reverse
3.Slow
decal58-6520
58-6520
1.Grease
1.Warning-donottouchorapproachmovingbelts;remove
106-2655
decal106-2655
theignitionkeyandreadtheinstructionsbeforeservicing orperformingmaintenance.
6
Page 7
1.Warning—donottouchthehotsurface.
decal106-5517
106-5517
decal110-2068
110-2068
1.ReadtheOperator'sManual.
decal112-9028
112-9028
1.Warning—stayawayfrommovingparts;keepallguardsin place.
decal114-4466
114-4466
decal107-3069
107-3069
1.Warning–thereisnorolloverprotectionwhentherollbaris down.
2.Toavoidinjuryordeathfromarolloveraccident,keepthe rollbarintheraisedandlockedpositionandweartheseat belt.Lowertherollbaronlywhenabsolutelynecessary;do notweartheseatbeltwhentherollbarisdown.
3.ReadtheOperator'sManual;driveslowlyandcarefully.
decal110-2067
110-2067
1.Main(25A)3.Charge(25A)
2.PTO(10A)4.Auxiliary(15A)
116-1716
1.Fuel6.Hourmeter
2.Empty
3.Half
4.Full9.Neutral
5.Battery
7.PTO
8.Parkingbrake
10.Operator-presenceswitch
decal116-1716
7
Page 8
116-5988
1.Parkingbrake—engaged2.Parking
brake—disengaged
116-8726
1.ReadtheOperator’sManualfortherecommendedhydraulic uid.
decal116-5988
decal117-3848
117-3848
1.Thrownobjecthazard—keepbystandersasafedistance awayfromthemachine.
2.Thrownobjecthazard,mower-donotoperatethemachine withoutthedeector ,dischargecover,orgrasscollection systeminplace.
3.Cutting/dismembermentofhandorfoot—stayawayfrom movingparts;keepallguardsandshieldsinplace.
decal116-8726
decal117-3864
117-3864
117-0346
1.Fuelleakhazard—readtheOperator'sManual;donot attempttoremovetherollbar;donotweld,drill,ormodify therollbarinanyway.
1.ReadtheOperator’s
Manual.
2.Filltobottomofllerneck; warning—donotoverll thetank.
decal119-6807
119-6807
1.Warning—nostep
decal117-0346
8
Page 9
126-2055
1.Wheellugnuttorque95ft-lb(129N∙m)(4x)
2.Wheelhubnuttorque235ft-lb(319N∙m)
3.ReadandunderstandtheOperator’sManualbefore performinganymaintenance,checktorqueafterrst100 hoursthenevery500hoursthereafter.
126-4659
1.Warning—hotpulley;allowtocool.
133-8062
decal126-2055
decal126-4659
decal133-8062
121-7551
1.Powertakeoff(PTO)4.Continuous-variable
2.Choke5.Slow
3.Fast
decal121-7551
setting
9
Page 10
1.ReadtheOperator’s Manual.
2.Lock
decal126-4398
126-4398
3.Unlock
decal127-0326
1.Camlock2.Camunlock
MachineswithMyRide™Only
132-5063
decal132-5063
127-0326
1.ReadtheOperator's Manual.
2.Height-of-cut
1.Maximumdrawbarpull36 kg(80lb)
3.Removethekeyfrom
131-4036
2.ReadtheOperator's
theignitionandreadthe Operator'sManualbefore performingmaintenance orservicingthemachine.
Manual.
decal136-5508
136-5508
1.Beltrouting
decal131-4036
10
Page 11
125-9383
1.Checkthehydraulicuidevery50operatinghours.3.Checkthetirepressureevery50operatinghours.
2.ReadtheOperator’sManualforinformationonlubricating themachine.
4.ReadtheOperator’sManualbeforeservicingorperforming maintenance.
decal125-9383
11
Page 12
132-0871
Note:Thismachinecomplieswiththeindustrystandardstabilitytestinthestaticlateralandlongitudinaltestswiththemaximum
recommendedslopeindicatedonthedecal.ReviewtheinstructionsforoperatingthemachineonslopesintheOperator’sManualas wellastheconditionsinwhichyouwouldoperatethemachinetodeterminewhetheryoucanoperatethemachineinthoseconditions onthatdayandatthatsite.Changesintheterraincanresultinachangeinslopeoperationforthemachine.Ifpossible,keepthe cuttingunitsloweredtothegroundwhileoperatingthemachineonslopes.Raisingthecuttingunitswhileoperatingonslopescan causethemachinetobecomeunstable.
decal132-0871
1.Warning—readtheOperator’sManual;donotoperatethis machineunlessyouaretrained;wearhearingprotection.
4.Ramphazard—whenloadingontoatrailer,donotusedual ramps;onlyuseasingularrampwideenoughforthemachine andthathasaninclinelessthan15°;backuptheramp(in reverse)anddriveforwardofftheramp.
2.Cutting,dismembering,andentanglementhazard—keep handsawayfrommovingparts;keepallguardsandshieldsin
5.Bodilyharmhazard—donotcarrypassengers;lookbehind youwhenmowinginreverse.
place.
3.Thrownobjecthazard—keepbystandersaway.6.Tippinghazardonslopes—donotuseonslopesnearopen water;donotuseonslopesgreaterthan15°.
132-5067
MachineswithMyRide™Only
decal132-5067
12
Page 13
ProductOverview
ControlPanel
g008951
Figure5
Figure4
1.Side-dischargedeector
2.Height-of-cutdecklift
pedal
3.Parking-brakelever10.Fuelcap
4.Transportlock11.Mowerdeck
5.Controls12.Casterwheel
6.Motion-controllevers13.Front-shockassembly
7.Rollbar
8.Rear-shockassembly (machineswithMyRide™ only)
9.Seatbelt
(machineswithMyRide™ only)
Controls
Becomefamiliarwithallthecontrolsbeforeyoustart theengineandoperatethemachine(Figure4and
Figure5).
1.Blade-controlswitch (powertakeoff)
g029631
2.Chokecontrol
3.Throttlecontrol6.Fuses
4.Hour meter/Safety-interlock display
5.Ignitionswitch
HourMeter
Thehourmeterrecordsthenumberofhoursthe enginehasoperated.Itoperateswhentheengine isrunning.Usethesetimesforschedulingregular maintenance(Figure6).
FuelGauge
Thefuelgaugeislocatedwithinthehourmeter,and thebarslightupwhenthekeyswitchisintheON position(Figure6).
Theindicatorlightappearswhenthefuellevelislow (approximately1gallonremaininginthefueltank).
Safety-InterlockIndicators
Therearesymbolsonthehourmeterthatindicate withablacktrianglethattheinterlockcomponentis positionedcorrectly(Figure6).
Battery-IndicatorLight
IfyouturnthekeyswitchtotheONpositionfora fewseconds,thebatteryvoltagedisplaysinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating level(Figure6).
13
Page 14
Figure6
1.Fuelgauge(bars)4.Safety-interlocksymbols
2.Batterylight
3.Hourmeter
5.Lowfuelindicatorlight
ThrottleControl
Thethrottlecontrolstheenginespeed,andithasa continuous-variablesettingfromtheSLOWtoFAST position(Figure5).
Fuel-ShutoffValve
Closethefuel-shutoffvalvewhentransportingor storingthemachine;refertoUsingtheFuel-Shutoff
Valve(page32).
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesisavailableforusewiththemachine toenhanceandexpanditscapabilities.Contact yourAuthorizedServiceDealerorauthorizedT oro
g008950
distributororgotowww.Exmark.comforalistofall approvedattachmentsandaccessories.
Toensureoptimumperformanceandcontinuedsafety certicationofthemachine,useonlygenuineT oro replacementpartsandaccessories.Replacement partsandaccessoriesmadebyothermanufacturers couldbedangerous,andsuchusecouldvoidthe productwarranty.
ChokeControl
Usethechokecontroltostartacoldengine.
Blade-ControlSwitch(Power Takeoff)
Theblade-controlswitch,representedbya power-takeoff(PTO)symbol,engagesand disengagespowertothemowerblades(Figure5).
KeySwitch
Thekeyswitch,usedtostartandshutofftheengine, has3positions:OFF,RUN,andSTART.Referto
StartingtheEngine(page25).
Motion-ControlLevers
Usethemotion-controlleverstodrivethemachine forward,reverse,andturneitherdirection(Figure4).
Neutral-LockPosition
UsetheNEUTRAL-LOCKpositionwiththe safety-interlocksystemtoengageandtodetermine theNEUTRALposition.
14
Page 15
Specications
Note:Specicationsanddesignaresubjecttochangewithoutnotice.
Width
48-inchDeck52-inchDeck60-inchDeck72-inchDeck
Withoutthedeck
Deectorup
Deectordown
Length
Rollbarup
Rollbardown
116cm122cm135cm150cm
(46inches)(48inches)(53inches)(59inches)
137cm137cm157cm187cm
(54inches)(54inches)(62inches)(74inches)
161cm173cm192cm222cm
(64inches)(68inches)(76inches)(88inches)
48-inchDeck52-inchDeck60-inchDeck72-inchDeck
201cm201cm211cm219cm
(79inches)(79inches)(83inches)(86inches)
206cm206cm215cm223cm
(81inches)(81inches)(85inches)(88inches)
Height
48-inchDeck52-inchDeck60-inchDeck72-inchDeck
178cm178cm179cm179cm
Rollbarup
(70inches)(70inches)(71inches)(71inches)
118cm1 18cm1 19cm119cm
Rollbardown
(47inches)(47inches)(47inches)(47inches)
Weight
ModelWeight
74949
74950
74952
74959
75932
75936
78953
495kg(1,092lb)
541kg(1,193lb)
475kg(1,048lb)
588kg(1,296lb)
565kg(1,246lb)
589kg(1,298lb)
492kg(1,085lb)
15
Page 16
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
BeforeOperation

BeforeOperationSafety

•Donotllcontainersinsideavehicleoronatruck
ortrailerbedwithaplasticliner.Alwaysplace containersontheground,awayfromyourvehicle beforelling.
•Removetheequipmentfromthetruckortrailer
andrefuelitwhileitisontheground.Ifthisisnot possible,thenrefuelfromaportablecontainer ratherthanafuel-dispensernozzle.
•Donotoperatethemachinewithouttheentire
exhaustsysteminplaceandinproperworking condition.

GeneralSafety

•Neverallowchildrenoruntrainedpeopleto
operateorservicethemachine.Localregulations mayrestricttheageoftheoperator.Theowner isresponsiblefortrainingalloperatorsand mechanics.
•Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
•Knowhowtostopthemachineandshutoffthe
enginequickly.
•Checkthatoperator-presencecontrols,safety
switches,andshieldsareattachedandfunctioning properly.Donotoperatethemachineunlessthey arefunctioningproperly.
•Beforemowing,alwaysinspectthemachineto
ensurethattheblades,bladebolts,andcutting assembliesareingoodworkingcondition. Replacewornordamagedbladesandboltsinsets topreservebalance.
•Inspecttheareawhereyouwillusethemachine
andremoveallobjectsthatthemachinecould throw.
•Keepthefuel-dispensernozzleincontactwith
therimofthefueltankorcontaineropeningat alltimesuntilfuelingiscomplete.Donotusea nozzlelock-opendevice.
•Ifyouspillfuelonyourclothing,changeyour
clothingimmediately.Wipeupanyfuelthatspills.
•Neveroverllthefueltank.Replacethefuelcap
andtightenitsecurely.
•Storefuelinanapprovedcontainerandkeepit
outofthereachofchildren.Neverbuymorethan a30-daysupplyoffuel.
•Donotllthefueltankcompletelyfull.Addfuelto
thefueltankuntilthelevelis6to13mm(1/4to 1/2inch)belowthebottomofthellerneck.This emptyspaceinthetankallowsfueltoexpand.
–Avoidprolongedbreathingofvapors.
–Keepyourfaceawayfromthenozzleandfuel
tankopening.
–Avoidcontactwithskin;washoffspillswith
soapandwater.
•Evaluatetheterraintodeterminetheappropriate
equipmentandanyattachmentsoraccessories requiredtooperatethemachineproperlyand safely.

FuelSafety

•Toavoidpersonalinjuryorpropertydamage,use
extremecareinhandlingfuel.Fuelvaporsare ammableandexplosive.
•Extinguishallcigarettes,cigars,pipes,andother
sourcesofignition.
•Useonlyanapprovedfuelcontainer.
•Donotremovethefuelcaporaddfueltothefuel
tankwhiletheengineisrunningorwhilehot.
•Donotrefuelthemachineindoors.
•Donotstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.
16
Page 17

AddingFuel

RecommendedFuel

•Forbestresults,useonlyclean,fresh(lessthan
30daysold),unleadedgasolinewithanoctane ratingof87orhigher((R+M)/2ratingmethod).
•Ethanol:Gasolinewithupto10%ethanol
(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse.
Neverusegasolinethatcontainsmorethan 10%ethanolbyvolume,suchasE15(contains
15%ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.
•Donotusegasolinecontainingmethanol.
•Donotstorefueleitherinthefueltankorfuel
containersoverthewinterunlessyouuseafuel stabilizer.
Note:Donotllthefueltankcompletelyfull.
Theemptyspaceinthetankallowsthefuelto expand.
•Donotaddoiltogasoline.

UsingStabilizer/Conditioner

Useafuelstabilizer/conditionerinthemachineto providethefollowingbenets:
•Keepsfuelfreshlongerwhenusedasdirectedby
thefuel-stabilizermanufacturer
•Cleanstheenginewhileitruns
•Eliminatesgum-likevarnishbuildupinthefuel
system,whichcauseshardstarting
Important:Donotusefueladditives
containingmethanolorethanol.
Addthecorrectamountoffuelstabilizer/conditioner tothefuel.
Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshfuel.Tominimize thechanceofvarnishdepositsinthefuelsystem, usefuelstabilizeratalltimes.

FillingtheFuelTank

1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey.
g027726
Figure7

PerformingDaily Maintenance

Beforestartingthemachineeachday ,performthe EachUse/DailyprocedureslistedinMaintenance
(page35).

BreakinginaNewMachine

Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhen new,placingadditionalloadontheengine.Allow 40to50hoursofbreak-intimefornewmachinesto developfullpowerandbestperformance.
4.Cleanaroundthefuel-tankcap.
5.Fillthefueltanktothebottomofthellerneck (Figure7).
17
Page 18

Usingthe Rollover-ProtectionSystem (ROPS)

WARNING
Toavoidinjuryordeathfromrollover,keep therollbarinthefullyraised,lockedposition andusetheseatbelt.
Ensurethattheseatissecuredtothe machine.
WARNING
Thereisnorolloverprotectionwhentheroll barisinthedownposition.
•Lowertherollbaronlywhenabsolutely necessary.
•Donotweartheseatbeltwhentherollbar isinthedownposition.
•Driveslowlyandcarefully.
•Raisetherollbarassoonasclearance permits.
•Checkcarefullyforoverheadclearances (i.e.,branches,doorways,electricalwires) beforedrivingunderanyobjectsanddo notcontactthem.

LoweringtheRollBar

Important:Lowertherollbaronlywhen
absolutelynecessary.
1.T olowertherollbar,applyforwardpressureto theupperpartoftherollbar.
2.Pullbothknobsoutandrotatethem90degrees sotheyarenotengaged(Figure8).
3.Lowertherollbartothedownposition(Figure
8).
Figure8
1.Rollbarintheupright position
2.ROPSknobinthelatched position
3.PulltheROPSknobout.6.Rollbarinthefolded
4.RotatetheROPSknob90 degrees.
5.ROPSknobinthe unlatchedposition
position

RaisingtheRollBar

Important:Alwaysusetheseatbeltwiththeroll
barintheraisedposition.
1.Raisetherollbartotheoperatingpositionand rotatetheknobsuntiltheymovepartiallyinto thegrooves(Figure8).
g228804
2.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarsothatthepins snapintopositionwhentheholesalignwiththe pins(Figure8).
3.Pushontherollbarandensurethatbothpins areengaged.
18
Page 19

UsingtheSafety-Interlock System

TestingtheSafety-Interlock System

ServiceInterval:Beforeeachuseordaily
WARNING
Ifthesafety-interlockswitchesare disconnectedordamaged,themachinecould operateunexpectedly,causingpersonal injury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.

Understandingthe Safety-InterlockSystem

Thesafety-interlocksystemisdesignedtopreventthe enginefromstartingunless:
•Theparkingbrakeisengaged.
•Theblade-controlswitch(PTO)isdisengaged.
•Themotion-controlleversareintheNEUTRAL-LOCK
position.
Thesafety-interlocksystemalsoisdesignedtoshut offtheenginewhenthemotion-controlleversare movedfromtheNEUTRAL-LOCKpositionwiththe parkingbrakeengagedorifyourisefromtheseat whenthePTOisengaged.
Thehourmeterhassymbolstonotifytheuserwhen theinterlockcomponentisinthecorrectposition. Whenthecomponentisinthecorrectposition,a trianglelightsupinthecorrespondingsquare.
Testthesafety-interlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorized ServiceDealerrepairthesafetysystemimmediately .
1.Sitontheseat,engagetheparkingbrake,and movetheblade-controlswitch(PTO)totheON position.Trystartingtheengine;theengine shouldnotstart.
2.Sitontheseat,engagetheparkingbrake,and movetheblade-controlswitch(PTO)totheOFF position.Moveeithermotion-controlleverout oftheNEUTRAL-LOCKposition.Trystartingthe engine;theengineshouldnotstart.Repeatfor theothercontrollever.
3.Sitontheseat,engagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,disengage theparkingbrake,engagetheblade-control switch(PTO),andriseslightlyfromtheseat;the engineshouldshutoff.
4.Sitontheseat,engagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Nowstartthe engine.Whiletheengineisrunning,center eithermotioncontrolandmove(forwardor reverse);theengineshouldshutoff.Repeatfor othermotioncontrol.
5.Sitontheseat,disengagetheparkingbrake, movetheblade-controlswitch(PTO)totheOFF position,andmovethemotion-controllevers totheNEUTRAL-LOCKposition.Trystartingthe engine;theengineshouldnotstart.
Figure9
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
g009181
19
Page 20

PositioningtheSeat

Theseatcanmoveforwardandbackward.Position theseatwhereyouhavethebestcontrolofthe machineandaremostcomfortable(Figure10).

MachineswithoutMyRide™ SuspensionSystem

Tounlatchtheseat,pushtheseatlatchforward (Figure12).

UnlatchingtheSeat

MachineswithMyRide™ SuspensionSystem

Figure10
g019754
1.Seatlatch2.Seat
Figure12
g008956

ChangingtheSeat Suspension

MachineswithoutMyRide™ SuspensionSystemOnly
Theseatisadjustabletoprovideasmoothand comfortableride.Positiontheseatwhereyouare mostcomfortable.
Toadjustit,turntheknobinfronteitherdirectionto providethebestcomfort(Figure13).
Figure11
g024881
Figure13
1.Seat-suspensionknob
g204507
20
Page 21

AdjustingtheMyRide™ SuspensionSystem

MachineswithMyRide™ SuspensionSystemOnly
TheMyRide™suspensionsystemadjuststoprovide asmoothandcomfortableride.Youcanadjustthe rear2-shockassembliestoquicklyandeasilychange thesuspensionsystem.Positionthesuspension systemwhereyouaremostcomfortable.

AdjustingtheRear-Shock Assemblies

Theslotsfortherear-shockassemblieshave detentpositionsforreference.Youcanpositionthe rear-shockassembliesanywhereintheslot,notjust inthedetentpositions.
Thefollowinggraphicshowsthepositionforasoftor rmrideandthedifferentdetentpositions(Figure14).
Adjusttherear-shockassemblies(Figure15).
g030024
Figure14
1.Firmestposition3.Detentsintheslots
2.Softestposition
Note:Ensurethattheleftandrightrear-shock
assembliesarealwaysadjustedtothesamepositions.
g030065
g030019
Figure15
21
Page 22
DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible
foraccidentsthatmaycausepersonalinjuryor propertydamage.
•Wearappropriateclothing,includingeye
protection;longpants;slip-resistant,substantial footwear;andhearingprotection.Tiebacklong hairanddonotwearloosejewelry .
•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Nevercarrypassengersonthemachineandkeep
bystandersandpetsawayfromthemachine duringoperation.
•Operatethemachineonlyingoodvisibilitytoavoid
holesorhiddenhazards.
•Avoidmowingonwetgrass.Reducedtraction
couldcausethemachinetoslide.
•Ensurethatalldrivesareinneutral,theparking
brakeisengaged,andyouareintheoperating positionbeforeyoustarttheengine.
•Keepyourhandsandfeetawayfromthecutting
units.Keepclearofthedischargeopeningatall times.
•Lookbehindanddownbeforebackinguptobe
sureofaclearpath.
•Usecarewhenapproachingblindcorners,shrubs,
trees,orotherobjectsthatmayobscureyour vision.
•Donotmowneardrop-offs,ditches,or
embankments.Themachinecouldsuddenlyroll overifawheelgoesovertheedgeoriftheedge givesway.
•Stopthebladeswheneveryouarenotmowing.
•Stopthemachine,shutofftheengine,remove
thekey,andinspectthebladesafterstrikingan objectorifthereisanabnormalvibrationinthe machine.Makeallnecessaryrepairsbefore resumingoperation.
•Slowdownandusecautionwhenmakingturns
andcrossingroadsandsidewalkswiththe machine.Alwaysyieldtheright-of-way.
•Disengagethedrivetothecuttingunit,shutoffthe
engine,andremovethekeybeforeadjustingthe heightofcut(unlessyoucanadjustitfromthe operatingposition).
•Neverrunanengineinanareawhereexhaust
gasesareenclosed.
•Neverleavearunningmachineunattended.
•Beforeleavingtheoperatingposition(including
toemptythecatchersortounclogthechute),do thefollowing:
–Stopthemachineonlevelground. –Disengagethepowertakeoffandlowerthe
attachments. –Engagetheparkingbrake. –Shutofftheengineandremovethekey. –Waitforallmovingpartstostop.
•Donotoperatethemachinewhenthereistherisk
oflightning.
•Donotusethemachineasatowingvehicleunless
ithasahitchinstalled.
•Donotchangethegovernorspeedoroverspeed
theengine.
•Useonlyaccessoriesandattachmentsapproved
byToro.
•Thismachineproducessoundlevelsinexcess
of85dBAattheoperator’searandcancause hearinglossthroughextendedperiodsof exposure.
g229846
Figure16
1.Wearhearingprotection.

RolloverProtectionSystem (ROPS)Safety

•Donotremovetherollbarfromthemachine.
•Ensurethattheseatbeltisattachedandthatyou
canreleaseitquicklyinanemergency.
•Alwayswearyourseatbeltwhentherollbarisup.
•Checkcarefullyforoverheadobstructionsanddo
notcontactthem.
•Keeptherollbarinsafeoperatingconditionby
thoroughlyinspectingitperiodicallyfordamage andkeepingallthemountingfastenerstight.
•Replaceadamagedrollbar.Donotrepairoralter
it.

SlopeSafety

•Slopesareamajorfactorrelatedtolossofcontrol
androlloveraccidents,whichcanresultinsevere
22
Page 23
injuryordeath.Theoperatorisresponsiblefor safeslopeoperation.Operatingthemachineon anysloperequiresextracaution.Beforeusingthe machineonaslope,dothefollowing:
–Reviewandunderstandtheslopeinstructions
inthemanualandonthemachine.
–Useanangleindicatortodeterminethe
approximateslopeangleofthearea.
–Neveroperateonslopesgreaterthan15
degrees.
–Evaluatethesiteconditionsofthedayto
determineiftheslopeissafeformachine operation.Usecommonsenseandgood judgmentwhenperformingthisevaluation. Changesintheterrain,suchasmoisture,can quicklyaffecttheoperationofthemachineon aslope.
•Identifyhazardsatthebaseoftheslope.Do
notoperatethemachineneardrop-offs,ditches, embankments,water,orotherhazards.The machinecouldsuddenlyrolloverifawheelgoes overtheedgeortheedgecollapses.Keepasafe distance(twicethewidthofthemachine)between themachineandanyhazard.Useawalk-behind machineorahandtrimmertomowthegrassin theseareas.
1.SafeZone—usethe machinehereonslopes lessthan15degreesor atareas.
2.DangerZone—usea walk-behindmowerand/or ahandtrimmeronslopes greaterthan15degrees andneardrop-offsor water.
3.Water
g221745
Figure17
4.W=widthofthemachine
5.Keepasafedistance (twicethewidthofthe machine)betweenthe machineandanyhazard.
•Avoidstarting,stopping,orturningthemachineon
slopes.Avoidmakingsuddenchangesinspeedor direction;turnslowlyandgradually.
•Donotoperateamachineunderanyconditions
wheretraction,steering,orstabilityisinquestion. Beawarethatoperatingthemachineonwet grass,acrossslopes,ordownhillmaycausethe machinetolosetraction.Lossoftractiontothe drivewheelsmayresultinslidingandalossof brakingandsteering.Themachinecanslideeven ifthedrivewheelsarestopped.
•Removeormarkobstaclessuchasditches,holes,
ruts,bumps,rocks,orotherhiddenhazards.T all grasscanhideobstacles.Uneventerraincould overturnthemachine.
•Useextracarewhileoperatingwithaccessoriesor
attachments,suchasgrass-collectionsystems. Thesecanchangethestabilityofthemachine andcausealossofcontrol.Followdirectionsfor counterweights.
•Ifpossible,keepthedeckloweredtotheground
whileoperatingonslopes.Raisingthedeckwhile operatingonslopescancausethemachineto becomeunstable.

EnteringtheOperator’s Position

Usethemowerdeckasasteptogetintothe operator’sposition(Figure18).
g029797
Figure18
23
Page 24
OperatingtheParking
OperatingtheMower
Brake
Alwaysengagetheparkingbrakewhenyoustopthe machineorleaveitunattended.

EngagingtheParkingBrake

Parkthemachineonalevelsurface.
Figure19
Blade-ControlSwitch(PTO)
Theblade-controlswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.

EngagingtheBlade-Control Switch(PTO)

Note:Engagingtheblade-controlswitch(PTO)with
thethrottlepositionathalforlesscausesexcessive weartothedrivebelts.
g029632
Figure21
g008945

DisengagingtheParkingBrake

Figure20

DisengagingtheBlade-Control Switch(PTO)

g009174
Figure22
g029829

OperatingtheThrottle

YoucanmovethethrottlecontrolbetweenFASTand SLOWpositions(Figure23).
AlwaysusetheFASTpositionwhenengagingthePTO.
g008946
Figure23
24
Page 25

OperatingtheChoke

StartingtheEngine

Usethechoketostartacoldengine.
1.Pullupthechokeknobtoengagethechoke beforeusingthekeyswitch(Figure24).
2.Pushdownthechokeknobtodisengagethe chokeaftertheenginehasstarted(Figure24).
Important:Donotengagestarterformorethan5
secondsatatime.Iftheenginefailstostart,wait 15secondsbetweenattempts.Failuretofollow theseinstructionscanburnoutthestartermotor.
Note:Y oumayneedmultipleattemptstostartthe
enginethersttimeafteraddingfueltoanemptyfuel system.
Figure24
1.ONposition2.OFFposition
g008959
g032328
Figure25
25
Page 26

ShuttingOfftheEngine

CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethemachinewhile itisunattended.
Alwaysremovethekeyandengagethe parkingbrakewhenleavingthemachine unattended.

UsingtheMotion-Control Levers

Figure26
Important:Makesurethatthefuel-shutoffvalve
isclosedbeforetransportingorstoringthe machine,asfuelleakagemayoccur.Engagethe parkingbrakebeforetransporting.Makesurethat youremovethekeyasthefuelpumpmayrunand causethebatterytolosecharge.
g004532
Figure27
1.Motion-control lever—NEUTRAL-LOCK position
2.Center,unlockedposition5.Frontofmachine
3.Forward
4.Backward

DrivingtheMachine

g027337
Thedrivewheelsturnindependently,poweredby hydraulicmotorsoneachaxle.Y oucanturn1side inreversewhileyouturntheotherforward,causing themachinetospinratherthanturn.Thisgreatly improvesthemachinemaneuverabilitybutmay requiresometimeforyoutoadapttohowitmoves.
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolintheFASTpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
26
Page 27
WARNING
Themachinecanspinveryrapidly.You maylosecontrolofthemachineandcause personalinjuryordamagetothemachine.
•Usecautionwhenmakingturns.
•Slowthemachinedownbeforemaking sharpturns.

DrivingForward

Note:Theengineshutsoffwhenyoumovethe
traction-controlwiththeparkingbrakeengaged.
Tostopthemachine,pullthemotion-controllevers totheNEUTRALposition.
1.Disengagetheparkingbrake;referto
DisengagingtheParkingBrake(page24).
2.Movetheleverstothecenter,unlockedposition.
3.T ogoforward,slowlypushthemotion-control leversforward(Figure28).

DrivingBackward

1.Movetheleverstothecenter,unlockedposition.
2.T ogobackward,slowlypullthemotion-control leversrearward(Figure29).
Figure28
g008953
Figure29
g008952
27
Page 28

UsingtheSideDischarge

Themowerhasahingedgrassdeectorthat dispersesclippingstothesideanddowntowardthe turf.
DANGER
Withoutagrassdeector,dischargecover,or acompletegrass-catcherassemblymounted inplace,youandothersareexposedtoblade contactandthrowndebris.Contactwith rotatingmowerblade(s)andthrowndebris willcauseinjuryordeath.
•Neverremovethegrassdeectorfromthe mowerdeckbecausethegrassdeector routesmaterialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
•Neverputyourhandsorfeetunderthe mowerdeck.
•Nevertrytoclearthedischargearea ormowerbladesunlessyoumovethe blade-controlswitch(PTO)totheOFF position,rotatethekeyswitchtotheOFF position,andremovethekeyfromthekey switch.

AdjustingtheHeightofCut

UsingtheTransportLock

Thetransportlockhas2positions,andisusedwith thedeck-liftpedal.ThereisaLOCKpositionand anUNLOCKpositionforthetransportpositionofthe mowerdeck(Figure30).
•Makesurethatthegrassdeectorisinthe downposition.
g229103
Figure30
Transport-LockPositions
1.Transportlockknob3.UNLOCKposition—The mowerdeckdoesnotlock intothetransportposition.
2.LOCKposition—The
mowerdecklocksintothe transportposition.
28
Page 29

AdjustingtheHeight-of-CutPin

AdjustingtheAnti-Scalp
Theheight-of-cutisadjustedfrom25to140mm(1 to5-1/2inches)in6mm(1/4inch)incrementsby relocatingtheclevispinintodifferentholelocations.
1.Movethetransportlocktothelockposition.
2.Pushonthedeck-liftpedalwithyourfoot,and raisethemowerdecktothetransportposition (alsothe140mm(5-1/2inches)cuttingheight position)asshowninFigure31.
3.T oadjust,rotatethepin90degreesandremove thepinfromtheheight-of-cutbracket(Figure
31).
4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesired,and insertthepin(Figure31).
5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.
Rollers
Wheneveryouchangetheheight-of-cut,adjustthe heightoftheanti-scalprollers.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Adjusttheanti-scalprollersasshowninFigure
32,Figure33,andFigure34.
1.Deck-liftpedal
2.Cut-of-heightpin
Figure31
3.Transportlock
g029955
Figure32
1.Anti-scalproller4.Flangenut
2.Spacer
3.Bushing
g027343
1.Anti-scalproller3.Flangenut
2.Bushing4.Bolt
5.Bolt
g029956
Figure33
29
Page 30
Figure34
1.Anti-scalproller4.Flangenut
2.Spacer
3.Bushing
5.Bolt
AdjustingtheFlowBafe
g029957
Figure35
g027727
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendations foruse.Adjustmentsvarybygrasstype,moisture content,andtheheightofthegrass.
CamLocks
Thisprocedureisapplicableonlytomachineswiththe ow-bafelocks.Certainmodelshavenutsandbolts inplaceoftheow-bafelocksandcanbeadjusted thesame.
Youcanadjustthemower-dischargeowfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.T oadjustthecamlocks,swingtheleverupto loosenthecamlock(Figure35).
4.Adjustthebafeandcamlocksintheslotsto thedesireddischargeow.
5.Swingtheleverbackovertotightenthebafe andcamlocks(Figure35).
Note:Iftheenginepowerdrawsdownandthe
mowergroundspeedisthesame,openupthebafe.

PositionA

Thisisthefullrearposition.Thesuggestedusefor thispositionisasfollows:
•Short,lightgrassmowingconditions
•Dryconditions
•Smallergrassclippings
•Propelsgrassclippingsfartherawayfromthe
mower
6.Ifthecamlocksdonotlockthebafeintoplace oritistootight,loosentheleverandthenrotate thecamlock.
Note:Adjustthecamlockuntilthedesired
lockingpressureisachieved.
g005832
Figure36
30
Page 31

PositionB

Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.
Figure37
OperatingTips
UsingtheFastThrottleSetting
Forbestmowingandmaximumaircirculation,operate theengineattheFASTposition.Airisrequiredto thoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower deckinuncutgrass.Alwaystrytohave1sideofthe mowerdeckfreefromuncutgrass,whichallowsair tobedrawnintothemowerdeck.
CuttingaLawnfortheFirstTime
Cutgrassslightlylongerthannormaltoensurethat thecuttingheightofthemowerdeckdoesnotscalp anyunevenground.However,thecuttingheight usedinthepastisgenerallythebestonetouse.
g005833
Whencuttinggrasslongerthan15cm(6inches)tall, youmaywanttocutthelawntwicetoensurean acceptablequalityofcut.
CuttingaThirdoftheGrassBlade

PositionC

Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows:
•Tall,densegrassmowingconditions
•Wetconditions
•Lowerstheengine-powerconsumption
•Allowsincreasedgroundspeedinheavyconditions
Itisbesttocutonlyaboutathirdofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrows moreslowly.
AlternatingtheMowingDirection
Alternatethemowingdirectiontokeepthegrass standingstraight.Thisalsohelpsdisperseclippings, whichenhancesdecompositionandfertilization.
MowingatCorrectIntervals
Grassgrowsatdifferentratesatdifferenttimesof theyear.T omaintainthesamecuttingheight,mow moreofteninearlyspring.Asthegrassgrowthrate slowsinmidsummer,mowlessfrequently.Ifyou cannotmowforanextendedperiod,rstmowata highcuttingheight,thenmowagain2dayslaterata lowerheightsetting.
UsingaSlowerCuttingSpeed
Toimprovecutquality,useaslowergroundspeed incertainconditions.
Figure38
g005834
AvoidingCuttingTooLow
Whenmowinguneventurf,raisethecuttingheight toavoidscalpingtheturf.
StoppingtheMachine
Ifyoumuststoptheforwardmotionofthemachine whilemowing,aclumpofgrassclippingsmay
31
Page 32
dropontoyourlawn.T oavoidthis,moveontoa previouslycutareawiththebladesengagedoryou candisengagethemowerdeckwhilemovingforward.
KeepingtheUndersideofthe MowerDeckClean
Cleanclippingsanddirtfromtheundersideofthe mowerdeckaftereachuse.Ifgrassanddirtbuildup insidethemowerdeck,cuttingqualitywilleventually becomeunsatisfactory.
MaintainingtheBlade(s)
Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.T earingandshredding turnsgrassbrownattheedges,whichslowsgrowth andincreasesthechanceofdisease.Checkthe mowerbladesaftereachuseforsharpness,and foranywearordamage.Filedownanynicksand sharpenthebladesasnecessary.Ifabladeis damagedorworn,replaceitimmediatelywitha genuineT ororeplacementblade.
g008948
Figure39
1.ONposition2.OFFposition

Usingthe Drive-Wheel-Release Valves

AfterOperation

AfterOperationSafety

GeneralSafety

•Cleangrassanddebrisfromthecuttingunits,
mufers,andenginecompartmenttohelpprevent res.Cleanupoilorfuelspills.
•Shutoffthefuelandremovethekeybeforestoring
ortransportingthemachine.
•Disengagethedrivetotheattachmentwhenever
youaretransportingornotusingthemachine.
•Allowtheenginetocoolbeforestoringthemachine
inanyenclosure.
•Neverstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such asonawaterheateroronotherappliances.

UsingtheFuel-Shutoff Valve

Thefuel-shutoffvalveislocatedundertheseat.Move theseatforwardtoaccessit.
Closethefuel-shutoffvalvefortransport,maintenance, andstorage.
Ensurethatthefuel-shutoffvalveisopenwhen startingtheengine.
WARNING
Handsmaybecomeentangledintherotating drivecomponentsbelowtheenginedeck, whichcouldresultinseriousinjury.
Shutofftheengine,removethekey,andallow allmovingpartstostopbeforeaccessingthe drive-wheel-releasevalves.
WARNING
Theengineandhydraulic-driveunitscan becomeveryhot.T ouchingahotengineor hydraulic-driveunitscancausesevereburns.
Allowtheengineandhydraulic-driveunits tocoolcompletelybeforeaccessingthe drive-wheel-releasevalves.
Thedrive-wheel-releasevalvesarelocatedinthe backofeachhydraulic-driveunit,undertheseat.
Note:Makesurethatthereleasevalvesareinthe
fullyhorizontalpositionwhenoperatingthemachine; otherwise,severedamagetothehydraulicsystem canoccur.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
32
Page 33
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Rotatetherelease-valveleversverticallytopush themachine(Figure40).
Note:Thisallowshydraulicuidtobypassthe
pump,enablingthewheelstoturn.
4.Disengagetheparkingbrakebeforepushing themachine.

TransportingtheMachine

Useaheavy-dutytrailerortrucktotransportthe machine.Useafull-widthramp.Ensurethatthetrailer ortruckhasallthenecessarybrakes,lighting,and markingasrequiredbylaw.Pleasecarefullyreadall thesafetyinstructions.Knowingthisinformationcould helpyouorbystandersavoidinjury.Refertoyour localordinancesfortrailerandtie-downrequirements.
WARNING
Drivingonthestreetorroadwaywithout turnsignals,lights,reectivemarkings,ora slow-moving-vehicleemblemisdangerous andcanleadtoaccidents,causingpersonal injury.
Donotdrivethemachineonapublicstreet orroadway.

SelectingaTrailer

Figure40
1.Verticaltopushthe
machine
5.Rotatethereleasevalvelevershorizontallyto runthemachine(Figure40).
2.Horizontaltorunthe machine
WARNING
g015123
Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath(Figure41).
•Useonlyafull-widthramp;donotuse individualrampsforeachsideofthe machine.
•Donotexceeda15-degreeanglebetween therampandthegroundorbetweenthe rampandthetrailerortruck.
•Ensurethatthelengthoframpisatleast4 timesaslongastheheightofthetraileror truckbedtotheground.Thisensuresthat rampangledoesnotexceed15degreeson atground.
33
Page 34
1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
2.Ifapplicable,connectthetrailerbrakesand lights.
3.Lowertheramp,ensuringthattheangle betweentherampandthegrounddoesnot exceed15degrees(Figure41).
4.Backthemachineuptheramp(Figure42).
Figure42
g028043
1.Full-widthrampinstowed position
2.Sideviewoffull-width rampinloadingposition
3.Notgreaterthan 15degrees

LoadingtheMachine

Figure41
4.Rampisatleast4times aslongastheheightof thetrailerortruckbedto theground
5.H=heightofthetraileror truckbedtotheground
6.Trailer
1.Backthemachineupthe ramp.
2.Drivethemachineforward downtheramp.
5.Shutofftheengine,removethekey,andengage theparkingbrake.
6.Tiedownthemachinenearthefrontcaster wheelsandtherearbumperwithstraps,chains, cable,orropes(Figure43).Refertolocal regulationsfortie-downrequirements.
g027996
WARNING
Loadingamachineontoatrailerortruck increasesthepossibilityoftip-overandcould causeseriousinjuryordeath.
•Useextremecautionwhenoperatinga machineonaramp.
•Backthemachineuptherampanddriveit forwarddowntheramp.
•Avoidsuddenaccelerationordeceleration whiledrivingthemachineonarampas thiscouldcausealossofcontrolora tip-oversituation.
g027338
Figure43
1.Tie-downloops

UnloadingtheMachine

1.Lowertheramp,ensuringthattheangle betweentherampandthegrounddoesnot exceed15degrees(Figure41).
2.Drivethemachineforwarddowntheramp (Figure42).
34
Page 35
Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst100hours
Aftertherst250hours
Beforeeachuseordaily
Every50hours
Every100hours
MaintenanceProcedure
•Checkthewheellug-nuttorque.
•Checkthewheel-hubslotted-nuttorque.
•Checktheparkingbrakeadjustment.
•Changethehydraulicltersandhydraulicuidwhenusinganytypeofuid.
•Checkthesafetysystem.
•ForKawasakiengines—checktheengine-oillevel.
•ForKohlerengines—checktheaircleanerfordirty,looseordamagedparts.
•ForKohlerengines—checktheengine-oillevel.
•Checktheseatbelt.
•Checktherollbarknobs.
•Cleantheenginescreenandtheoilcooler.
•Checkandcleanthehydraulic-unitshrouds.
•Inspecttheblades.
•Cleanthemowerdeck.
•Cleanthesuspensionsystem.
•Checkthesparkarrester(ifequipped).
•Checkthetirepressure.
•Inspectthebeltsforcracksandwear.
•Checkthehydraulic-uidlevel.
•Lubricatethemowerdeck-liftpivots.
•ForKawasakiengines—changetheengineoil(moreoftenindirtyordusty conditions).
•ForKawasakiengines—replaceorcleanandgapthesparkplug.
•ForKohlerengines—changetheengineoil(moreoftenindirtyordustyconditions).
•Checkandcleanengine-coolingnsandshrouds.
Every200hours
Every250hours
Every300hours
•ForKawasakiengines—changetheengine-oillter(moreoftenindirtyordusty conditions).
•ForKohlerengines—changetheengine-oillter(moreoftenindirtyordusty conditions).
•ForKohlerengines—checkthesparkplug(s).
•ForKohlerengines—Replacethefuellter(moreoftenindusty,dirtyconditions).
•ForKawasakiengines—replacetheprimaryairlter(moreoftenindustyorsandy conditions).
•ForKawasakiengines—checkthesafetyairlter.(moreoftenindustyorsandy conditions).
•ForKohlerengines—serviceorreplacetheair-cleanerfoamelement(moreoften underdusty,dirtyconditions).
•ChangethehydraulicltersandhydraulicuidwhenusingMobil®1uid(more oftenindirtyordustyconditions).
•ForKawasakiengines—Checkandadjustthevalveclearance.SeeanAuthorized ServiceDealer.
35
Page 36
MaintenanceService
Every500hours
Interval
MaintenanceProcedure
•ForKawasakiengines—replacethesafetyairlter.(moreoftenindustyorsandy conditions).
•ForKohlerengines—replacetheair-cleanerpaperelement(moreoftenunderdusty, dirtyconditions).
•ForKohlerengines—replacethesparkplug(s).
•ForKawasakiengines—Replacethefuellter(moreoftenindusty,dirtyconditions).
•Checkthewheellug-nuttorque.
•Checkthewheel-hubslotted-nuttorque.
•Adjustthecaster-pivotbearing.
•Checktheparkingbrakeadjustment.
•ChangethehydraulicltersandhydraulicuidwhenusingToro®HYPR-OIL™500 hydraulicuid(moreoftenindirtyordustyconditions).
Monthly
Yearly
Yearlyorbeforestorage
•Checkthebatterycharge.
•Greasethepump-belt-idlerarm.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Repackthefrontcaster-wheelbearings(moreoftenindirtyordustyconditions).
•Lubricatethecaster-wheelhubs.
•Paintchippedsurfaces.
•Checkallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineowner'smanualforadditionalmaintenanceprocedures.
CAUTION
Ifyouleavethekeyintheswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.
Shutofftheengineandremovethekeyfromtheswitchbeforeyouperformanymaintenance.
Pre-Maintenance Procedures

MaintenanceSafety

•Beforerepairingthemachinedothefollowing:
–Disengagethedrives.
–Engagetheparkingbrake.
–Shutofftheengineandremovethekey.
–Disconnectthespark-plugwire.
•Parkthemachineonalevelsurface.
•Cleangrassanddebrisfromthecuttingunit,
drives,mufers,andenginetohelppreventres.
•Cleanupoilorfuelspills.
•Donotallowuntrainedpersonneltoservicethe
machine.
•Usejackstandstosupportthemachineand/or
componentswhenrequired.
•Carefullyreleasepressurefromcomponentswith
storedenergy.
•Disconnectthebatteryorremovethespark-plug
wirebeforemakinganyrepairs.Disconnectthe
negativeterminalrstandthepositiveterminal last.Connectthepositiveterminalrstand negativelast.
•Usecarewhencheckingtheblades.Wrapthe
blade(s)orwearthicklypaddedgloves,anduse cautionwhenservicingthem.Onlyreplaceblades; donotstraightenorweldthem.
•Keepyourhandsandfeetawayfrommoving
parts.Ifpossible,donotmakeadjustmentswith theenginerunning.
•Keepallpartsingoodworkingcondition
andallhardwaretightened,especiallythe blade-attachmentbolts.Replaceallwornor damageddecals.
•Neverinterferewiththeintendedfunctionofa
safetydeviceorreducetheprotectionprovided byasafetydevice.Checktheirproperoperation regularly.
•UseonlygenuineTororeplacementparts.
•Checktheparkingbrakeoperationfrequently.
Adjustandserviceasrequired.
36
Page 37
Lubrication

GreasingtheMachine

Greasemorefrequentlywhenoperatingconditions areextremelydustyorsandy.
GreaseType:No.2lithiumormolybdenumgrease
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleanthegreasettingswitharag.
Note:Makesurethatyouscrapeanypaintoff
thefrontofthetting(s).
4.Connectagreaseguntothetting.
5.Pumpgreaseintothettingsuntilgreasebegins tooozeoutofthebearings.

GreasingtheMowerDeck

ServiceInterval:Yearly—Greasethepump-belt-idler
arm.
Yearly—Greasethefrontcasterpivots(more oftenindirtyordustyconditions).
Yearly—Repackthefrontcaster-wheelbearings (moreoftenindirtyordustyconditions).
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Greasethemowerdeckidler-pulleypivotuntil greasecomesoutthebottom(Figure45).
6.Wipeupanyexcessgrease.

AddingLightOilorSpray Lubrication

ServiceInterval:Every100hours
Lubricatethedeck-liftpivots.
Figure44
g185957
Figure45
4.Greasethedrive-belt-idlerarm(Figure46).
g017050
g009030
Figure46
37
Page 38
5.Removethedustcapandadjustthecaster pivots.
Note:Keepthedustcapoffuntilgreasingis
done.
6.Removethehexplug.
7.Threadagreasettingintothehole.
8.Pumpgreaseintothettinguntilitoozesout aroundthetopbearing.
9.Removethegreasettinginthehole.
10.Installthehexpluganddustcap(Figure47).

Lubricatingthe Caster-WheelHubs

ServiceInterval:Y early
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
g006115
Figure48
Figure47
11.Greasethecaster-wheelbearings(Figure47).
1.Sealguard2.Spacernutwithwrench
ats
g027339
3.Raisethemowerforaccess.
4.Removethecasterwheelfromthecasterforks.
5.Removethesealguardsfromthewheelhub.
6.Removeaspacernutfromtheaxleassemblyin thecasterwheel.
Note:Thread-lockingadhesivehasbeen
appliedtolockthespacernutstotheaxle.
7.Removetheaxle(withtheotherspacernutstill assembledtoit)fromthewheelassembly.
8.Pryoutsealsandinspectbearingsforwearor damageandreplaceifnecessary.
9.Packthebearingswithageneral-purpose grease.
10.Insert1bearingand1newsealintothewheel.
Note:Replacetheseals.
11.Iftheaxleassemblyismissingbothspacernuts, applyathread-lockingadhesiveto1spacernut andthreaditontotheaxlewiththewrenchats facingoutward.
Note:Donotthreadthespacernutallof
thewayontotheendoftheaxle.Leave approximately3mm(1/8inch)fromtheouter surfaceofthespacernuttotheendoftheaxle insidethenut.
38
Page 39
12.Inserttheassemblednutandaxleintothewheel onthesideofthewheelwiththenewsealand bearing.
13.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
14.Insertthesecondbearingandnewsealintothe wheel.
15.Applyathread-lockingadhesivetothesecond spacernut,andthreaditontotheaxlewiththe wrenchatsfacingoutward.
16.T orquethenutto8to9N∙m(75to80in-lb), loosen,thentorqueto2to3N∙m(20to25in-lb).
Note:Makesurethattheaxledoesnotextend
beyondeithernut.
17.Installthesealguardsoverthewheelhub,and insertthewheelintothecasterfork.
18.Installthecasterboltandtightenthenutfully.
Important:Topreventsealandbearingdamage,
checkthebearingadjustmentoften.Spinthe castertire.Thetireshouldnotspinfreely(more than1or2revolutions)orhaveanysideplay.If thewheelspinsfreely,adjustthetorqueonthe spacernutuntilthereisaslightamountofdrag. Applyanotherlayerofthread-lockingadhesive.
39
Page 40
EngineMaintenance

IdentifyingtheEngine

Usethefollowinggraphictoidentifytheengineyouhaveandproceedtothesectionlistedbelowforservice (Figure49).
Figure49
1.Kawasakiengine2.Kohlerengine
g230252
•ForKawasakienginemaintenance,refertoServicingaKawasaki
•ForKohlerenginemaintenance,refertoServicingaKohler

EngineSafety

•Shutofftheenginebeforecheckingtheoilor
addingoiltothecrankcase.
•Keepyourhands,feet,face,clothing,andother
bodypartsawaythemuferandotherhotsurfaces.
®
Engine(page40).
®
Engine(page45).
ServicingaKawasaki
®
Engine
ThissectionisonlyformachineswithKawasaki engines.Ifyourenginelooksliketheoneshownin
Figure50,youhaveaKawasakiengine.
Important:Refertoyourengineowner’smanual
foradditionalmaintenanceprocedures.
g036714
Figure50
40
Page 41
ServicingtheAirCleaner
ServiceInterval:Every250hours—ForKawasaki
engines—replacetheprimaryair lter(moreoftenindustyorsandy conditions).
Every250hours—ForKawasaki engines—checkthesafetyairlter.(moreoften industyorsandyconditions).
Every500hours—ForKawasaki engines—replacethesafetyairlter. (moreoftenindustyorsandyconditions).
Note:Checktheltersmorefrequentlyifthe
operatingconditionsareextremelydustyorsandy .
RemovingtheFilters
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Releasethelatchesontheaircleanerandpull theair-cleanercoverofftheair-cleanerbody (Figure51).
Important:Donotattempttocleanthe
safetylter.Ifthesafetylterisdirty,then theprimarylterisdamaged.Replaceboth lters.
7.Inspecttheprimarylterfordamagebylooking intothelterwhileshiningabrightlightonthe outsideofthelter.
Note:Holesinthelterappearasbrightspots.
Ifthelterisdamaged,discardit.
InspectingtheFilters
1.Inspectthesafetylter.Ifitisdirty ,replaceboth thesafetyandprimarylters.
Important:Donotattempttocleanthe
safetylter.Ifthesafetylterisdirty,then theprimarylterisdamaged.
2.Inspecttheprimarylterfordamagebylooking intothelterwhileshiningabrightlightonthe outsideofthelter.Iftheprimarylterisdirty , bent,ordamaged,replaceit.
Note:Holesinthelterappearasbrightspots.
Donotcleantheprimarylter.
InstallingtheFilters
Figure51
1.Air-cleanerbody4.Air-cleanercover
2.Primarylter5.Safetylter
3.Latch
4.Cleantheinsideoftheair-cleanercoverwith compressedair.
5.Gentlyslidetheprimarylteroutofthe air-cleanerbody(Figure51).
Important:Topreventenginedamage,always
operatetheenginewithbothairltersandthe coverinstalled.
1.Ifyouareinstallingnewlters,checkeachlter forshippingdamage.
Note:Donotuseadamagedlter.
2.Ifyouarereplacingtheinnerlter,carefullyslide itintothelterbody(Figure51).
3.Carefullyslidetheprimarylteroverthesafety lter(Figure51).
Note:Ensurethattheprimarylterisfully
g001883
seatedbypushingontheouterrimwhile installingit.
Important:Donotpressonthesoft,inside
areaofthelter.
4.Installtheair-cleanercoverandsecurethe latches(Figure51).
Note:Avoidknockingthelterintothesideof
thebody.
6.Removethesafetylteronlytoreplaceit.
41
Page 42
ServicingtheEngineOil
Engine-OilSpecications
OilType:Detergentoil(APIserviceSF ,SG,SH,SJ,
orSL)
CrankcaseCapacity:
•Model74949,74950,75932,75936—2.3L(78
oz)withalterchange;2.1L(71oz)without alterchange
•Model74952,78953—2.1L(71oz)withalter
change;1.8L(61oz)withoutalterchange
Viscosity:Seethetablebelow.
3.T okeepdirt,grassclippings,etc.,outofthe engine,cleantheareaaroundtheoil-llcapand dipstickbeforeremovingit(Figure53).
g008804
Figure52
Note:Although10W-40engineoilisrecommended
formostconditions,youmayneedtochangeoil viscositytoaccommodateatmosphericconditions. Using20W-50engineoilinhigherambient temperaturescanreduceoilconsumption.
CheckingtheEngine-OilLevel
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
Important:Ifyouoverllorunderlltheengine
crankcasewithoilandruntheengine,youmay damagetheengine.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
Note:Ensurethattheengineiscoolsothatthe
oilhashadtimetodrainintothesump.
g037096
g194611
Figure53
ChangingtheEngineOil
ServiceInterval:Every100hours(moreoftenindirty
ordustyconditions).
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunfor5minutes.
Note:Thiswarmstheoilsothatitdrainsbetter.
42
Page 43
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoensurethatthe oildrainscompletely.
3.Disengagetheblade-controlswitch(PTO)and engagetheparkingbrake.
4.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
5.Draintheoilfromtheengine(Figure54).
6.Slowlypourapproximately80%ofthespecied oilintothellertubeandslowlyaddthe additionaloiltobringittotheFullmark(Figure
55).
g008804
Figure54
g027660
Figure55
7.Starttheengineanddrivetoaatarea.
8.Checktheoillevelagain.
g027734
43
Page 44
ChangingtheEngine-OilFilter
ServicingtheSparkPlug
ServiceInterval:Every200hours—ForKawasaki
engines—changetheengine-oil lter(moreoftenindirtyordusty conditions).
1.Draintheoilfromtheengine;refertoChanging
theEngineOil(page42).
2.Changetheengine-oillter(Figure56).
ServiceInterval:Every100hours
Ensurethattheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplugandagappingtoolorfeelergaugeto checkandadjusttheairgap.Installanewsparkplug ifnecessary.
TypeofSparkPlug:NGK
®
BPR4ESorequivalent
AirGap:0.75mm(0.03inch)
RemovingtheSparkPlug
1.Parkthemachineonalevelsurface,disengage
g008804
theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleantheareaaroundthebaseoftheplug(s)to keepdirtanddebrisoutoftheengine.
4.Locateandremovethesparkplug(s)asshown inFigure57.
Figure56
Note:Ensurethattheoil-ltergaskettouches
theengine,andthenturntheoillteranextra 3/4turn.
3.Fillthecrankcasewiththepropertypeofnew oil;refertoServicingtheEngineOil(page42).
g009922
g027478
g027477
Figure57
44
Page 45
CheckingtheSparkPlug
Important:Donotcleanthesparkplug(s).
Alwaysreplacethesparkplug(s)whenithasa blackcoating,wornelectrodes,anoilylm,or cracks.
Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty .
Setthegapto0.75mm(0.03inch).
Figure58
ServicingaKohler
ThissectionisonlyformachineswithKohlerengines. IfyourenginelooksliketheoneshowninFigure60, youhaveaKohlerengine.
®
Engine
Important:Refertoyourengineowner’smanual
foradditionalmaintenanceprocedures.
g206628
g230254
Figure60
InstallingtheSparkPlug
Figure59
ServicingtheAirCleaner
ServiceInterval:Beforeeachuseordaily—For
Kohlerengines—checktheair cleanerfordirty ,looseordamaged parts.
Every250hours—ForKohlerengines—service orreplacetheair-cleanerfoamelement(more oftenunderdusty ,dirtyconditions).
Every500hours—ForKohlerengines—replace theair-cleanerpaperelement(moreoftenunder dusty,dirtyconditions).
Thisengineisequippedwithareplaceable, high-densitypaperandfoamair-cleanerelement.
g027661
Checktheaircleanerdailyorbeforestartingthe engine.Checkforabuildupofdirtanddebrisaround theair-cleanersystem.Keepthisareaclean.Also, checkforlooseordamagedcomponents.Replaceall bentordamagedair-cleanercomponents.
Note:Operatingtheenginewithlooseordamaged
air-cleanercomponentscouldallowunlteredairinto theengine,causingprematurewearandfailure.
Note:Servicetheaircleanermoreoftenunderdusty,
dirtyconditions.
RemovingtheFilters
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
45
Page 46
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Releasethelatchesontheaircleanerand pulltheair-inletcoverofftheair-cleanerbody (Figure61).
4.Cleantheair-inletscreenandcover.
5.Installtheair-inletcoverandsecureitwiththe latches(Figure61).
g012997
Figure62
Figure61
1.Air-inletcover3.Air-cleanerbody
2.Air-inletscreen4.Latch
6.Releasethelatchesontheaircleanerandpull theair-cleanercoverofftheair-cleanerbody (Figure62).
7.Cleantheinsideoftheair-cleanercoverwith compressedair.
8.Gentlyslidetheprimarylteroutofthe air-cleanerbody(Figure62).
Note:Avoidknockingthelterintothesideof
thebody.
9.Removetheinnerlteronlyifyouintendto replaceit.
1.Innerlter
2.Primarylter
3.Air-cleanercover
g012996
10.Inspecttheprimarylterfordamagebylooking intothelter,whileshiningabrightlightonthe
4.Latch
5.Air-cleanerbody
outsideofthelter.
Note:Holesinthelterwillappearasbright
spots.Ifthelterisdamaged,discardit.
ServicingtheFoamElement
1.Washthefoamelementinliquidsoapand warmwater.Whentheelementisclean,rinse itthoroughly.
2.Drytheelementbysqueezingitinacleancloth.
Important:Replacethefoamelementifit
istornorworn.
ServicingthePaperElement
1.Gentlytapthepaperelementtodislodgedirt.
Important:Neverattempttocleantheinner
lter.Ifthesafetylterisdirty ,thenthe primarylterisdamaged.Replaceboth lters.
Note:Donotwashthepaperelementoruse
pressurizedair,asthiswilldamagetheelement.
Note:Replaceadirty,bent,ordamaged
element.Handlethenewelementcarefully; donotuseifthesealingsurfacesarebentor damaged.
2.Cleantheair-cleanerbaseasrequired,and checkthecondition.
46
Page 47
InstallingtheFilters
Important:Topreventenginedamage,always
operatetheenginewithbothairltersandthe coverinstalled.
1.Ifyouareinstallingnewlters,checkeachlter forshippingdamage.
Note:Donotuseadamagedlter.
2.Ifyouarereplacingtheinnerlter,carefullyslide itintothelterbody(Figure62).
3.Carefullyslidetheprimarylteroverthesafety lter(Figure62).
Note:Ensurethattheprimarylterisfully
seatedbypushingontheouterrimwhile installingit.
Important:Donotpressonthesoft,inside
areaofthelter.
4.Installtheair-cleanercoverandsecurethe latches(Figure62).
ServicingtheEngineOil
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
Note:Ensurethattheengineiscoolsothatthe
oilhashadtimetodrainintothesump.
3.T okeepdirt,grassclippings,etc.,outofthe engine,cleantheareaaroundtheoil-llcapand dipstickbeforeremovingit(Figure53).
EngineOilSpecications
OilCapacity:withalterchange—1.65L(56oz);
withoutalterchange—1.50L(51oz)
Viscosity:Seethetablebelow.
Figure63
CheckingtheEngine-OilLevel
g017552
g194611
Figure64
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
Important:Ifyouoverllorunderlltheengine
crankcasewithoilandruntheengine,youmay damagetheengine.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
47
Page 48
ChangingtheEngineOil
ServiceInterval:Every100hours(moreoftenindirty
ordustyconditions).
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunfor5minutes.
Note:Thiswarmstheoilsothatitdrainsbetter.
2.Parkthemachinesothatthedrainsideisslightly lowerthantheoppositesidetoensurethatthe oildrainscompletely.
3.Disengagetheblade-controlswitch(PTO)and engagetheparkingbrake.
4.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
5.Draintheoilfromtheengine(Figure65).
g008804
g027734
Figure65
48
Page 49
6.Slowlypourapproximately80%ofthespecied oilintothellertubeandslowlyaddthe additionaloiltobringittotheFullmark(Figure
64).
g008804
Figure66
7.Starttheengineanddrivetoaatarea.
8.Checktheoillevelagain.
ChangingtheEngine-OilFilter
ServiceInterval:Every200hours—ForKohler
engines—changetheengine-oil lter(moreoftenindirtyordusty conditions).
1.Draintheoilfromtheengine;refertoChanging
theEngineOil(page48).
2.Changetheengine-oillter(Figure67).
g027660
g027477
Figure67
Note:Ensurethattheoil-ltergaskettouches
theengine,andthenturntheoillteranextra 3/4turn.
3.Fillthecrankcasewiththepropertypeofnew oil;refertoEngineOilSpecications(page47).
49
Page 50
ServicingtheSparkPlug
ServiceInterval:Every200hours—ForKohler
engines—checkthesparkplug(s).
Every500hours—ForKohlerengines—replace thesparkplug(s).
Type:ChampionXC12YC
AirGap:0.76mm(0.03inch)
RemovingtheSparkPlug
g206628
Figure69
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Cleantheareaaroundthebaseoftheplug(s)to keepdirtanddebrisoutoftheengine.
4.Locateandremovethesparkplug(s)asshown inFigure68.
InstallingtheSparkPlug
g009922
Figure70
g028109
Figure68
CheckingtheSparkPlug
Important:Donotcleanthesparkplug(s).
Alwaysreplacethesparkplug(s)whenithasa blackcoating,wornelectrodes,anoilylm,or cracks.
Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty .
Setthegapto0.76mm(0.03inch).
g027478
50
Page 51
CheckingtheSpark
FuelSystem
Arrester
ForMachineswithaSpark Arrester
ServiceInterval:Every50hours
WARNING
Hotexhaust-systemcomponentsmayignite fuelvaporsevenafteryoushutofftheengine. Hotparticlesexhaustedduringengine operationmayigniteammablematerials, resultinginpersonalinjuryorproperty damage.
Donotrefuelorruntheengineunlessthe sparkarresterisinstalled.
1.Parkthemachineonalevelsurface,disengage thePTO,andengagetheparkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Waitforthemufertocool.
4.Ifyouseeanybreaksinthescreenorwelds, replacethearrester.
Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every200hours(moreoftenin
dusty,dirtyconditions).
Every500hours/Yearly(whichevercomesrst) (moreoftenindusty,dirtyconditions).
Important:Installthefuellinehosesandsecure
withplastictiesthesameastheywereoriginally installedatthefactorytokeepthefuellineaway fromcomponentsthatcancausefuellinedamage.
Thefuellterislocatedneartheengineontheleft frontoftheengine.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Allowthemachinetocooldown.
4.Closethefuel-shutoffvalveundertheseat.
5.Replacethefuellter(Figure71).
5.Ifthescreenisplugged,removethearrester, shakelooseparticlesoutofthearrester,and cleanthescreenwithawirebrush(soakthe screeninsolventifnecessary).
6.Installthearresterontheexhaustoutlet.
g008963
Figure71
6.Openthefuel-shutoffvalve.

ServicingtheFuelTank

Donotattempttodrainthefueltank.Ensurethatan AuthorizedServiceDealerdrainsthefueltankand servicesanycomponentsofthefuelsystem.
51
Page 52
ElectricalSystem Maintenance

ElectricalSystemSafety

•Disconnectthebatterybeforerepairingthe
machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.
•Chargethebatteryinanopen,well-ventilated
area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated tools.

ServicingtheBattery

ServiceInterval:Monthly
RemovingtheBattery
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.RemovethebatteryasshowninFigure72.
g027728
Figure72
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalmachinecomponentscausing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.
•Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
WARNING
Incorrectlyremovingthecablesfrombattery coulddamagethemachineandcables, causingsparks.Sparkscancausethebattery gassestoexplode,resultinginpersonal injury.
•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
•Alwaysconnectthepositive(red)battery cablebeforeconnectingthenegative (black)cable.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
52
Page 53
ChargingtheBattery
InstallingtheBattery
WARNING
Chargingthebatteryproducesgassesthat canexplode.
Neversmokenearthebatteryandkeepsparks andamesawayfromthebattery.
Important:Alwayskeepthebatteryfullycharged
(1.265specicgravity).Thisisespecially importanttopreventbatterydamagewhenthe temperatureisbelow0°C(32°F).
1.Removethebatteryfromthechassis;referto
RemovingtheBattery(page52).
2.Chargethebatteryfor10to15minutesat25to 30Aorfor30minutesat10A.
Note:Donotoverchargethebattery.
3.Whenthebatteryisfullycharged,unplug thechargerfromtheelectricaloutlet,then disconnectthechargerleadsfromthebattery posts(Figure73).
4.Installthebatteryinthemachineandconnect thebatterycables;refertoInstallingtheBattery
(page53).
Note:Positionthebatteryinthetraywiththeterminal
postsoppositefromthehydraulictank(Figure72).
g032526
Figure74
Note:Donotrunthemachinewiththebattery
disconnected;electricaldamagemayoccur.
Figure73
1.Positive(+)batterypost3.Red(+)chargerlead
2.Negative(–)batterypost4.Black(–)chargerlead
g000960
53
Page 54

ServicingtheFuses

DriveSystem
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheckthe component/circuitforamalfunctionorshort.
Thefusesarelocatedontheconsoletotherightof theseat(Figure75).
1.T oreplacethefuses,pulloutonthefuseto removeit.
2.Installanewfuse(Figure75).
Figure75
1.Optionalaccessory(15A)4.Main(25A)
2.Charge(25A)
3.PTO(10A)
5.Console
Maintenance

CheckingtheSeatBelt

ServiceInterval:Beforeeachuseordaily
Inspecttheseatbeltforwear,cuts,andproper operationoftheretractorandbuckle.Replacethe seatbeltifitisdamaged.

CheckingtheRoll-Bar Knobs

ServiceInterval:Beforeeachuseordaily
WARNING
Toavoidinjuryordeathfromrollover,keep therollbarinthefullyraised,lockedposition andusetheseatbelt.
Ensurethattheseatissecuredtothe machine.
g008966
•Checkthatboththemountinghardwareandthe
knobsareingoodworkingcondition.
•Makesurethattheknobsarefullyengagedwith
therollbarintheraisedposition.
Note:Theupperhoopoftherollbarmayneed
tobepushedforwardorpulledrearwardtofully engagebothknobs(Figure76andFigure77).
54
Page 55

AdjustingtheTracking

1.Disengagetheblade-controlswitch(PTO).
2.Drivetoanopenatarea,movethe motion-controlleverstotheNEUTRAL-LOCK position.
3.Movethethrottlemidwaybetweenfastandslow.
4.Movebothmotion-controlleversalltheway forwarduntiltheybothhitthestopsintheT-slot.
5.Checkwhichwaythemachinetracks.
•Ifittrackstotheright,loosentheboltsand
adjusttheleftstopplaterearwardonthe leftT-slotuntilthemachinetracksstraight (Figure78).
•Ifittrackstotheleft,loosentheboltsand
adjusttherightstopplaterearwardonthe rightT-slotuntilthemachinetracksstraight (Figure78).
6.Tightenthestopplate(Figure78).
Figure76
1.Rollbarintheupright position
2.Roll-barknobinthe latchedposition
3.Pulltheroll-barknobout androtateit90degrees.
4.Rotatetheroll-barknob90 degrees.
5.Roll-barknobinthe unlatchedposition
6.Rollbarinthefolded position
Figure77
1.Engaged2.Partiallyengaged—donot operatewiththerollbarin thisposition.
g228804
g010153
Figure78
Leftcontrollevershown
g228981
1.Controllever3.Stopplate
2.Bolt
55
Page 56

CheckingtheTirePressure

ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthefrontandreartires at90kPa(13psi).Uneventirepressurecancause unevencut.Checkthetireswhentheyarecoldtoget themostaccuratepressurereading.
Figure79
g001055
g024121
Figure80

CheckingtheWheel-Lug Nuts

Checkandtorquethewheellugnutsto122to129 N∙m(90to95ft-lb).

CheckingtheWheel-Hub SlottedNut

ServiceInterval:Aftertherst100hours
Every500hours
Checkandensurethatthetorqueoftheslottednutis 286to352N∙m(211to260ft-lb).
Note:Donotuseanti-seizecompoundonwheelhub.
1.Slottednut

AdjustingtheCaster-Pivot Bearing

ServiceInterval:Every500hours/Yearly(whichever
comesrst)
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removethedustcapfromcasterandtighten thelocknut(Figure81).
4.Tightenthelocknutuntilthespringwashersare at,andthenbackoffa1/4turntoproperlyset thepreloadonthebearings(Figure81).
Important:Makesurethatthespring
washersareinstalledcorrectlyasshownin
Figure81.
5.Installthedustcap(Figure81).
56
Page 57
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Usinganaircompressor,blowoutanydebris fromunderthebrakepoleandaroundthebrake spacers(Figure83).
Figure81
1.Springwashers
2.Locknut
3.Dustcap

UsingtheClutchShim

Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchnolonger engagesconsistently,youcanremovetheshimto extendtheclutchlife.
g001297
Figure83
g010868
4.Checktheconditionofthewire-harnessleads, connectors,andterminals.
Note:Cleanorrepairasnecessary.
5.Verifythat12Vispresentattheclutchconnector whentheblade-controlswitch(PTO)switchis engaged.
6.Measurethegapbetweentherotorand armature.Ifthegapisgreaterthan1mm(0.04 inch),dothefollowingsteps:
A.Loosenbothbrake-mountingbolts1/2to1
fullturnasshowninFigure84.
Note:Donotremovethebrakepolefrom
theeldshell/armature.Thebrakepole hasworntomatchthearmatureandneeds tocontinuetomatchafteryouremovethe shimtoensureproperbraketorque.
Figure82
1.Armature5.Brakespacer
2.Fieldshell6.Re-gapshim
3.Rotor7.Brakepole
4.Brake-mountingbolt
RemovingtheClutchShim
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
g010869
g010870
Figure84
1.Brake-mountingbolt
B.Usingneedle-nosepliers,orbyhand,hold
thetabandremovetheshim(Figure85).
57
Page 58
Note:Donotdiscardtheshimuntilthe
clutchisfunctioningproperly.
g010873
Figure87
Figure85
1.Shim
C.Usingapneumaticline,blowoutanydebris
fromunderthebrakepoleandaroundthe brakespacers.
D.T orqueeachbolt(M6x1)to12.3to13.7
N∙m(9.5to10.5ft-lb).
E.Usinga0.25mm(0.01inch)thickfeeler
gauge,verifythatagapispresentbetween therotorandthearmaturefaceonboth sidesofthebrakepoleasshowninFigure
86andFigure87.
Note:Duetothewaytherotorandthe
armaturefaceswear(peaksandvalleys)it issometimesdifculttomeasurethegap accurately.
g010871
1.Feelergauge
•Ifthegapislessthan0.25mm(0.01
inch),theninstalltheshim;referto
UsingtheClutchShim(page57).
•Ifthegapissufcient,proceedtothe
safetycheckinstepF.
F.Performthefollowingsafetycheck:
i.Sitontheseatandstarttheengine.
ii.Makesurethatthebladesdonot
engagewiththeblade-controlswitch (PTO)intheOFFposition,andthat theclutchisdisengaged.
Iftheclutchdoesnotdisengage, installtheshimagain;refertoUsing
theClutchShim(page57).
iii.Engageanddisengagethe
blade-controlswitch(PTO)10 consecutivetimestoensurethatthe clutchisfunctioningproperly.
1.Feelergauge
g010872
Figure86
58
Page 59
CoolingSystem
Cleaningthe
Maintenance

CleaningtheEngineScreen andEngine-OilCooler

ServiceInterval:Beforeeachuseordaily
Removeanybuildupofgrass,dirt,orotherdebris fromtheoilcoolerandtheenginescreen(Figure88).
Engine-CoolingFinsand Shrouds
ServiceInterval:Every100hours/Yearly(whichever
comesrst)
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removetheair-intakescreen,therecoilstarter, andthefanhousing(Figure89).
4.Cleanthedebrisandgrassfromtheengine parts.
g008804
5.Installtheair-intakescreen,therecoilstarter, andthefanhousing(Figure89).
Figure88
Removeanybuildupofgrass,dirt,orotherdebris fromtheenginescreen.Thishelpsensureadequate coolingandcorrectenginespeedandreducesthe possibilityofoverheatingandmechanicaldamageto theengine(Figure85).
g009191
g004218
Figure89
1.Engineguard4.Fanhousing
2.Engineair-intakescreen
3.Bolt
5.Screw
59
Page 60

CheckingandCleaningthe Hydraulic-UnitShrouds

BrakeMaintenance
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Movetheseatforward.
4.Cleanthedebrisandgrassfromthe hydraulic-unitshrouds(Figure90).
5.Positiontheseat.

AdjustingtheParking Brake

ServiceInterval:Aftertherst100hours
Every500hoursthereafter
Note:Performthisprocedureattherecommended
serviceintervalorwhenabrakecomponenthasbeen removedorreplaced.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Raisethebackofthemachineandsupportthe machinewithjackstands.
CAUTION
g009922
Raisingthemachineforservice ormaintenancerelyingsolelyon mechanicalorhydraulicjackscouldbe dangerous.Themechanicalorhydraulic jacksmaynotbeenoughsupportormay malfunctionallowingthemachinetofall, whichcouldcauseinjury .
1.Hydraulic-unitshrouds
Figure90
Donotrelysolelyonmechanical orhydraulicjacksforsupport.Use adequatejackstandsorequivalent support.
4.Removethereartiresfromthemachine.
g015117
5.Removeanydebrisfromthebrakearea.
6.Rotatethedrive-wheelreleasehandleto thereleasedposition;refertoUsingthe
Drive-Wheel-ReleaseValves(page32).
7.Checktoseeifthereisavisiblegapbetween theL-bracketandthelinkagestop(Figure91).
60
Page 61
BeltMaintenance

InspectingtheBelts

ServiceInterval:Every50hours
Replacethebeltifitisworn.Thesignsofawornbelt includesquealingwhilethebeltisrotating;theblades slippingwhilecuttinggrass;andfrayededges,burn marks,andcracksonthebelt.

ReplacingtheMowerBelt

Figure91
LeftSideShown
1.L-bracket4.Rearlinkageassembly
2.Linkagestop
3.Gap
8.Disengagetheparkingbrake,thelevershould beinthedownposition.
9.Turnthewheelhubbyhandinbothdirections relativetothecaliper;thewheelhubshould movefreelybetweenthecaliper.
10.Ifagapisneededorthewheelhubdoesnot movefreely:
A.Disengagetheparkingbrake.
B.Disconnectandne-tunetherearlinkage
assembly:
5.Caliper
6.Wheelhub
•Shortenthelinktocreateagap.
•Lengthenthelinktoallowwheelhub
movement.
C.Connecttherearlinkageassembly.
11.Engagetheparkingbrakeandcheckthegap.
12.Repeatsteps8through12untilavisiblegapis achievedandthewheelhubrotatesfreely.
13.Repeatthisprocedureforthebrakeonthe oppositeside.
14.Rotatethedrive-wheelreleasehandleto theoperatingposition;refertoUsingthe
Drive-Wheel-ReleaseValves(page32).
g026961
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Lowerthemowertothe76mm(3inch) height-of-cut.
4.Pushthetabdownandremovethebeltcover (Figure92).
g027729
Figure92
5.Usearatchetinthesquareholeintheidlerarm toremovetensionontheidlerspring(Figure93).
6.Removethebeltfromthemower-deckpulleys.
7.Removethebeltguideonthespring-loaded idlerarm(Figure93).
8.Removetheexistingbelt.
9.Installthenewbeltaroundthemowerpulleys andtheclutchpulleyundertheengine(Figure
93).
15.Installthereartiresandtorquethelugnuts;refer toCheckingtheWheel-LugNuts(page56).
16.Removethejackstands.
61
Page 62
ReplacingtheHydraulic
g027730
Figure94
Figure93
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
armfortheratchet
6.Idler-greasetting
7.Beltguide
10.Installthebeltguideontheidlerarm(Figure93).
11.Usingtheratchetinthesquarehole,installthe idlerspring(Figure93).
Note:Makesurethatthespringendsare
seatedintheanchorgrooves.
12.Installthebeltcovers;slidethebeltcoverunder thesidecatchesandensurethatthetabisunder themetalcatch(Figure94).
g009038
Pump-DriveBelt
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removethemowerbelt;refertoReplacingthe
MowerBelt(page61).
4.Raisethemachineandsupportitwithjack stands(Figure95).
62
Page 63
Figure95
1.Idlerpulley
2.Clutchpulley6.Squareholeintheidler
3.Pump-drivebelt7.Idlerspring
4.Righthydraulic-pump pulley
5.Lefthydraulic-pumppulley
arm
ControlsSystem Maintenance

Adjustingthe Control-HandlePosition

Thereare2heightpositionsforthecontrol levers—highandlow.Removetheboltstoadjustthe heightfortheoperator.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait
g009039
forallmovingpartstostopbeforeleavingthe operatingposition.
3.Loosentheboltsandangenutsinstalledinthe levers(Figure96).
4.Aligntheleversinthefront-to-rearpositionby bringingtheleverstogethertotheNEUTRAL position,andslidethemuntiltheyarealigned, thentightenthebolts(Figure97).
5.Usearatchetinthesquareholeintheidlerarm toremovetheidlerspring(Figure95).
6.Unhooktheidlerspringfromtheframe(Figure
95).
7.Removethebeltfromthehydraulic-unit-drive pulleysandtheenginepulley.
8.Installthenewbeltaroundenginepulleyand the2drivepulleys.
9.Usingaratchetinthesquareholeintheidler arm,installtheidlerspringtotheframe(Figure
95).
10.Installthemowerbelt;refertoReplacingthe
MowerBelt(page61).
Figure96
1.Bolt(2)3.Controllever
2.Handle
4.Nut(2)
g009040
63
Page 64
4.Lowerdecktotheground.
5.Raisetherearofmachineupandsupportitwith jackstands(orequivalentsupport).
Note:Raisethemachinejusthighenoughto
allowthedrivewheelstoturnfreely.
6.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushion oftheseat.
Note:Theswitchisapartoftheseatassembly.
7.T emporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwire harness.
8.Starttheengineandrunitatfullthrottleand disengagethebrake.
Figure97
5.Iftheendsofthelevershitagainsteach other,refertoAdjustingtheMotion-Control
Neutral-LockPivot(page65).
6.Repeattoadjustthecontrollevers.

Adjustingthe Motion-ControlLinkage

Locatedoneithersideofthemachine,belowtheseat, arethepump-controllinkages.Rotatingtheendnut witha1/2-inchdeepsocketwrenchallowsnetuning adjustmentssothatthemachinedoesnotmovein neutral.Anyadjustmentsshouldbemadeforneutral positioningonly.
WARNING
Theenginemustberunningandthedrive wheelsturningsothatyoucanperformthe adjustments.Contactwithmovingpartsor hotsurfacesmaycausepersonalinjury .
g009195
Note:Beforestartingtheengine,ensurethat
theparkingbrakeisengagedandthatthe motion-controlleversareout.Youdonothave tobeintheseat.
9.Runthemachineforatleast5minuteswiththe driveleversatfullforwardspeedtobringthe hydraulicuiduptotheoperatingtemperature.
Note:Themotion-controlleversmust
beinneutralwhilemakinganynecessary adjustments.
10.Bringthemotion-controlleversintotheNEUTRAL position.
11.Adjustthepumpcontrolrodlengthsbyrotating thedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepin reverse(Figure98).
Keepyourngers,hands,andclothingclear ofrotatingcomponentsandhotsurfaces.
1.Disengagetheblade-controlswitch(PTO),move themotion-controlleverstotheNEUTRAL-LOCK position,andengagetheparkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Pushthedeck-liftpedal,andremovethe height-of-cutpin.
64
Page 65
1.Doublenuts
Figure98
g008620
Figure99
RightMotionControlShown
1.Torquethelocknutto23N∙m(17ft-lb).Theboltmust protrudepasttheendofthelocknutaftertorquing.
2.Mostresistance(rmestfeel)
3.Damper
g010187
4.Mediumresistance(mediumfeel)
5.Leastresistance(softestfeel)
12.Movethemotion-controlleverstotheREVERSE positionandwhileapplyingslightpressureto thelever,allowthereverse-indicatorspringsto bringtheleversbacktoneutral.
Note:Thewheelsmuststopturningorslightly
creepinreverse.
13.Shutoffthemachine.
14.Removethejumperwirefromthewireharness andplugtheconnectorintotheseatswitch.
15.Removethejackstands.
16.Raisethedeckandinstalltheheight-of-cutpin.
17.Checkthatthemachinedoesnotcreepin neutralwiththeparkbrakesdisengaged.

Adjustingthe Motion-ControlDamper

Youcanadjustthetopdamper-mountingbolttoobtain thedesiredmotion-controlleverresistance.Referto
Figure99formountingoptions.

Adjustingthe Motion-Control Neutral-LockPivot

Youcanadjusttheangednuttoobtainthedesired motion-controlleverresistancewhenmovingitto theNEUTRAL-LOCKposition.SeeFigure100for adjustmentoptions.
1.Loosenthejamnut.
2.Tightenorloosentheangednuttothedesired feel.
•Formoreresistance,tightentheangednut.
•Forlessresistance,loosentheangednut
3.Tightenthejamnut.
Figure100
1.Flangednut2.Jamnut
65
g008621
Page 66
HydraulicSystem
6.Remove1dipstickfromthehydraulicreservoir (Figure101).
Maintenance

HydraulicSystemSafety

•Seekimmediatemedicalattentionifuidisinjected
intoskin.Injecteduidmustbesurgicallyremoved withinafewhoursbyadoctor.
•Ensurethatallhydraulic-uidhosesandlinesare
ingoodconditionandallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.
•Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthigh-pressurehydraulic uid.
•Usecardboardorpapertondhydraulicleaks.
•Safelyrelieveallpressureinthehydraulicsystem
beforeperforminganyworkonthehydraulic system.

ServicingtheHydraulic System

7.Wipethedipstickoffandthreadthedipstickinto thereservoir.
8.Removethedipstickandlookattheend(Figure
101).
Important:Donotoverllthehydraulic
unitswithuid,asdamagemayoccur.Do notrunthemachinewithuidbelowtheadd mark.
9.Iftheuidlevelisattheaddmark,slowlypour onlyenoughuidintothehydraulicreservoirto raisetheleveltothefullorHline.
10.Installthedipstick.
11.Repeattheprocedurefortheoppositedipstick.
Hydraulic-FluidSpecications
Hydraulic-FluidT ype:Toro
hydraulicuidorMobil
®
®
HYPR-OIL
115W-50.
Important:Usethespecieduid.Otheruids
coulddamagethehydraulicsystem.
EachHydraulic-SystemFluidCapacity:1.5L(52
oz)persidewithlterchange
™
500
CheckingtheHydraulicFluid
ServiceInterval:Every50hours—Checkthe
hydraulic-uidlevel.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Allowtheengineandthehydraulicsystemto coolfor10minutes.
Note:Theoillevelonthedipstickisincorrect
whentheoilischeckedandthemachineishot.
g015459
Figure101
Eitherdipstickisusedinthemachine
1.Full3.H—meanshighlevel
2.Add4.Dipsticklocationsunder seat
4.Movetheseatforward.
5.Cleantheareaaroundthedipsticksof hydraulic-systemreservoirs(Figure101).
66
Page 67
ReplacingtheHydraulicFluidand Filters
ServiceInterval:Aftertherst250hours—Change
thehydraulicltersandhydraulic uidwhenusinganytypeofuid.
Every250hours—Changethehydrauliclters andhydraulicuidwhenusingMobil
®
1uid
(moreoftenindirtyordustyconditions).
Every500hours—Changethehydraulic ltersandhydraulicuidwhenusingT oro HYPR-OIL
™
500hydraulicuid(moreoftenin
dirtyordustyconditions).
Toreplacethehydraulicuid,theltersneedtobe removed.Replacebothatthesametime;referto
ReplacingtheHydraulicFluidandFilters(page67)
fortheoilspecications.
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch,andengagetheparking brake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Raisethemachineandsupportitwithjack stands(Figure102).
®
g008968
Figure103
Bottomviewofthemachine
1.Filterlocations
2.Hydrauliclter
6.Applyathincoatofhydraulicuidtotherubber gasketonthereplacementlter(Figure103).
7.Installthereplacementhydrauliclter.
8.Installthepump-drivebeltandthemowerbelt.
Figure102
1.Jackstands
4.Removeboththemowerbeltandthepump-drive belt;refertoReplacingtheMowerBelt(page
61)andReplacingtheHydraulicPump-Drive Belt(page62).
Note:Thispreventsoilfromgettingonthe
belts.
9.Removethejackstandsandlowerthemachine (Figure102).
10.Adduidtothehydraulicreservoirandcheck foranyleaks.
11.Cleanupanyspilleduid.
12.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.
13.Shutofftheengineandcheckforleaks.
14.Checktheuidlevelwhiletheuidiscold.
15.Ifrequired,adduidtothehydraulicreservoir.
g008970
Note:Donotoverll.
5.Placeadrainpanunderthelter,removetheold lter,andwipethesurfaceclean(Figure103).
67
Page 68

MowerDeck Maintenance

LevelingtheMowerDeck

LevelingtheDeck
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Checkthetirepressureinthedrivetires;referto
CheckingtheTirePressure(page56).
4.Positionthetransportlockinthelatching position.
5.Pushthedeck-liftpedalallthewayforwardand thedecklatchesatthe14cm(5-1/2inches) transportposition(Figure104).
9.Onbothsidesofthedeck,measurefromthe levelsurfacetothefronttipoftheblade(Postion A)asshowninFigure105.
Note:Themeasurementshouldread7.6mm
(3inches)
Figure105
1.7.6cm(3inch)atposition
Aiscorrect
2.8.3cm(3-1/4inch)at
positionBiscorrect
3.Measureherefromthe bladetiptothehard surface
4.MeasureatpositionAand Bonbothsides
g009196
Figure104
1.Deck-liftpedal
2.Height-of-cutpin
6.Inserttheheight-adjustmentpinintothe7.6cm (3inches)cutting-heightlocation.
3.Transportlock
10.Fine-tunetheadjustmentnutonthefront deck-liftassemblybyturningit(Figure106).
Note:T oincreasetheheight,turnthe
adjustmentnutclockwise;todecreasethe height,turnthenutcounterclockwise.
Note:Ifthefrontdecklinksdonothaveenough
adjustmenttoachieveaccuratecutheight,the single-pointadjustmentcanbeutilizedtogain moreadjustment.
g027343
7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.
8.Raisethedischargechute.
68
Page 69
Figure106
1.Adjustmentnut3.Reardeckadjustment
2.Jamnut4.Frontdeckadjustment
11.Toadjustthesingle-pointsystem,loosenthe 2boltsatthebottomoftheheight-of-cutplate (Figure107).
Note:Loosenortightenthesingle-point
adjustmentboltenoughtomovethe height-of-cutplatemountingboltsatleast1/3 thelengthoftheavailabletravelintheirslots. Thisregainssomeupanddownadjustmenton eachofthe4decklinks.
g017036
g027344
1.Single-pointadjustmentbolt
Figure108
13.Tightenthe2boltsatthebottomofthe height-of-cutplate(Figure107).
Note:Inmostconditions,thebackbladetip
shouldbeadjusted6.4mm(1/4inch)higher thanthefront.
Figure107
1.Boltsatthebottomoftheheight-of-cutplate
12.Ifthedeckistoolow,tightenthe single-point-adjustmentboltbyrotatingit clockwise.Ifthedeckistoohigh,loosen thesingle-point-adjustmentboltbyrotatingit counterclockwise(Figure108).
14.T orquethe2boltsto37to45N∙m(27to33ft-lb).
15.Onbothsidesofthedeck,measurefromthe levelsurfacetothebacktipoftheblade(postion B)asshowninFigure105.
Note:Themeasurementshouldread8.3cm
(3-1/4inches)
16.Finetunethescrewadjusterbyturningittoget
8.3mm(3-1/4inches)height(Figure106).
Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.
17.Measureuntilall4sidesarethecorrectheight.
18.Tightenallofthenutsonthedeck-lift-arm assemblies.
g027345
19.Lowerthedischargechute.
69
Page 70

ServicingtheCutting Blades

Toensureasuperiorqualityofcut,keeptheblades sharp.Forconvenientsharpeningandreplacement, youmaywanttokeepextrabladesonhand.
BladeSafety
Awornordamagedbladecanbreak,andapieceof thebladecouldbethrowntowardyouorbystanders, resultinginseriouspersonalinjuryordeath.Tryingto repairadamagedblademayresultindiscontinued safetycerticationoftheproduct.
•Inspectthebladesperiodicallyforwearordamage.
•Usecarewhencheckingtheblades.Wrapthe
bladesorweargloves,andusecautionwhen servicingtheblades.Onlyreplaceorsharpenthe blades;neverstraightenorweldthem.
•Onmulti-bladedmachines,takecareasrotating1
bladecancauseotherbladestorotate.
BeforeInspectingorServicingthe Blades
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey,and disconnectthespark-plugwiresfromthespark plugs.
g006530
Figure109
1.Cuttingedge3.Wear/slotforming
2.Curvedarea4.Crack
CheckingforBentBlades
1.Rotatethebladesuntiltheendsfaceforward andbackward.
2.Measurefromalevelsurfacetothecutting edge,positionA,oftheblades(Figure110).
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges(Figure109).
2.Iftheedgesarenotsharporhavenicks,remove andsharpentheblade;refertoSharpeningthe
Blades(page71).
3.Inspecttheblades,especiallyinthecurvedarea.
4.Ifyounoticeanycracks,wear,oraslotforming inthisarea,immediatelyinstallanewblade (Figure109).
Figure110
1.Measureherefromblade tohardsurface
3.Rotatetheoppositeendsofthebladesforward.
4.Measurefromalevelsurfacetothecuttingedge
ofthebladesatthesamepositionasinstep2 above.
2.PositionA
Note:Thedifferencebetweenthedimensions
obtainedinsteps2and4mustnotexceed3 mm(1/8inch).
Note:Ifthisdimensionexceeds3mm(1/8
inch),thebladeisbentandmustbereplaced.
g000975
70
Page 71
RemovingtheBlades
Replacethebladesiftheyhitasolidobject,orifthe bladeisoutofbalanceorbent.
1.Holdthebladeendusingaragorthicklypadded glove.
Note:Ifthebladeisnotbalanced,lesome
metalofftheendofthesailareaonly(Figure
112).
2.Removethebladebolt,curvedwasher,and bladefromthespindleshaft(Figure111).
Figure111
1.Sailareaoftheblade3.Curvedwasher
2.Blade4.Bladebolt
g000553
Figure113
1.Blade2.Balancer
3.Repeatthisprocedureuntilthebladeis balanced.
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure
111).
Important:Thecurvedpartoftheblade
mustpointupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthecurvedwasherandbladebolt(Figure
111).
Note:Installthecurved-washerconetoward
g004536
thebolthead.
3.T orquethebladeboltto1 15to150N∙m(85to 110ft-lb).

RemovingtheMowerDeck

SharpeningtheBlades
1.Usealetosharpenthecuttingedgeatboth endsoftheblade(Figure112).
Note:Maintaintheoriginalangle.
Note:Thebladeretainsitsbalanceifthesame
amountofmaterialisremovedfrombothcutting edges.
Figure112
1.Sharpenatoriginalangle.
2.Checkthebalanceofthebladebyputtingiton abladebalancer(Figure113).
Note:Ifthebladestaysinahorizontalposition,
thebladeisbalancedandcanbeused.
Lockoutthespring-loadeddeckarmsbeforeservicing orremovingthemowerdeck.
WARNING
Deck-liftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthe storedenergycancauseseriousinjuryor death.
Donotattempttodisassemblethedeckfrom thefrontframewithoutlockingoutthestored energy.
1.Parkthemachineonalevelsurface,disengage
g000552
theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Placetheheightadjustmentpininthe7.6cm(3 inch)cutting-heightlocation.
Note:Thislocksthedeck-liftarmsinthelowest
positionwhenthedeckisremovedandthe storedenergyinthedeckspringisreleased.
71
Page 72
4.Removethebeltcovers.
5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(Figure1 14).
6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(Figure114).
g010252
Figure115
1.Rightstabilizer
2.Deckstrut(rightsideshown)
3.Removetheshoulderboltandnut.
4.Removetheshoulderboltandnut.
8.Raisethedeckstrutsandsecuretheminthe raisedposition.
Figure114
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt
3.Spring-loadedidlerpulley
4.Ratchet
armfortheratchet
6.Idlergreasetting
7.Beltguide
7.Removeandretainthehardwareonbothsides ofthedeckasshowninFigure115.
9.Slidethedeckouttotherightsideofthe machine.
ReplacingtheGrass
g009038
Deector
WARNING
Anuncovereddischargeopeningcouldallow themachinetothrowobjectstowardyouor bystanders,resultinginseriousinjury.Also, contactwiththebladecouldoccur.
Neveroperatethemachineunlessyouinstall amulchplate,dischargedeector,orgrass collectionsystem.
1.Removethelocknut,bolt,spring,andspacer holdingthedeectortothepivotbrackets (Figure116).
2.Removethedamagedorworngrassdeector (Figure116).
72
Page 73
Figure116
1.Bolt
2.Spacer6.Grassdeector
3.Locknut
4.Spring
5.Springinstalled
7.J-hookendofspring
Cleaning

CleaningundertheMower Deck

ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,disengage theblade-controlswitch(PTO),andengagethe parkingbrake.
2.Shutofftheengine,removethekey ,andwait
g015594
forallmovingpartstostopbeforeleavingthe operatingposition.
3.RaisethemowerdecktotheTRANSPORT position.
CleaningtheSuspension
3.Placethespacerandthespringontograss deector.
4.Place1J-hookendofthespringbehindthe deckedge.
Note:Makesurethat1J-hookendofthe
springisinstalledbehindthedeckedgebefore installingtheboltasshowninFigure1 16.
5.Installtheboltandthenut.
6.Place1J-hookendofthespringaroundthe grassdeector(Figure1 16).
Important:Thegrassdeectormustbeable
torotate.Liftthedeectoruptothefullopen positionandensurethatitrotatesintothe fulldownposition.
System
MachineswithMyRide™ SuspensionSystemOnly
ServiceInterval:Beforeeachuseordaily
Usecompressedairtocleanthesuspensionsystem.
Note:Donotcleantheshockassemblieswith
pressurizedwater(Figure1 17).
g195820
Figure117

DisposingofWaste

Engineoil,batteries,hydraulicuid,andengine coolantarepollutantstotheenvironment.Disposeof theseaccordingtoyourstateandlocalregulations.
73
Page 74
Storage

StorageSafety

•Shutofftheengine,removethekey ,waitforall
movingpartstostop,andallowthemachineto coolbeforestoringit.
•Donotstorethemachineorfuelnearamesor
drainthefuelindoors.
•Removethekeyandstoreitinasafeplaceout
ofthereachofchildren.

CleaningandStorage

1.Disengagetheblade-controlswitch(PTO),and engagetheparkingbrake.
2.Shutofftheengine,removethekey ,andwait forallmovingpartstostopbeforeleavingthe operatingposition.
3.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especially theengineandhydraulicsystem.Cleandirtand chafffromtheoutsideoftheenginecylinder headnsandblowerhousing.
Important:Youcanwashthemachinewith
milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuse ofwater,especiallynearthecontrolpanel, engine,hydraulicpumps,andmotors.
4.Checktheparkingbrakeoperation;referto
EngagingtheParkingBrake(page24).
5.Servicetheaircleaner;refertoEngine
Maintenance(page40).
6.Greasethemachine;refertoLubrication(page
37).
7.Changethecrankcaseoil;refertoEngine
Maintenance(page40).
8.Checkthetirepressure;refertoCheckingthe
TirePressure(page56).
9.Changethehydrauliclters;refertoReplacing
theHydraulicFluidandFilters(page67).
13.Preparethemachineforstoragewhennon-use occursover30days.Preparethemachinefor storageasfollows:
A.Addapetroleum-based
stabilizer/conditionertofuelinthe tank.Followmixinginstructionsfrom thestabilizermanufacturer.Donotuse analcohol-basedstabilizer(ethanolor methanol).
Note:Afuelstabilizer/conditionerismost
effectivewhenmixedwithfreshfueland usedatalltimes.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystemfor5minutes.
C.Shutofftheengine,allowittocool,and
drainthefueltank.
D.Starttheengineandrunituntilitstops.
E.Disposeoffuelproperly.Recyclethefuel
accordingtolocalcodes.
Important:Donotstorefuelcontaining
stabilizer/conditionerlongerthan thedurationrecommendedbythe fuel-stabilizermanufacturer.
14.Removeandchecktheconditionofthespark plug(s);refertoServicingtheSparkPlug(page
44).Withthesparkplug(s)removedfromthe
engine,pour30ml(2tablespoons)ofengine oilintothesparkplughole.Usethestarterto cranktheengineanddistributetheoilinsidethe cylinder.Installthesparkplug(s).Donotinstall thewireonthesparkplug(s).
15.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.
16.Paintallscratchedorbaremetalsurfaces.Paint isavailablefromyourAuthorizedServiceDealer.
17.Storethemachineinaclean,drygarageor storagearea.Removethekeyfromtheswitch andkeepitoutofreachofchildrenorother unauthorizedusers.Coverthemachineto protectitandkeepitclean.
10.Chargethebattery;refertoChargingtheBattery
(page53).
11.Scrapeanyheavybuildupofgrassanddirt fromtheundersideofthemower,thenwashthe mowerwithagardenhose.
Note:Runthemachinewiththeblade-control
switch(PTO)engagedandtheengineathigh idlefor2to5minutesafterwashing.
12.Checktheconditionoftheblades;referto
ServicingtheCuttingBlades(page70).
74
Page 75
Troubleshooting
Problem
Thestarterdoesnotcrank.
Theenginedoesnotstart,startshard,or failstokeeprunning.
PossibleCauseCorrectiveAction
1.Theblade-controlswitchisengaged.1.Disengagetheblade-controlswitch.
2.Theparkingbrakeisdisengaged.2.Engagetheparkingbrake.
3.Themotion-controlleversarenotin theNEUTRAL-LOCKposition.
4.Y ouarenotsittingintheoperator’s seat.
5.Thebatteryisdead.
6.Theelectricalconnectionsare corrodedorloose.
7.Afuseisblown.7.Replacethefuse.
8.Arelayorswitchisdamaged.
1.Thefueltankisempty.1.Fillthefueltank.
2.Thefuel-shutoffvalveisclosed.2.Openthefuel-shutoffvalve.
3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.
4.Thethrottleisnotinthecorrect position.
5.Thereisdirtinthefuellter.5.Replacethefuellter.
6.Dirt,water,orstalefuelisinfuel system.
7.Theaircleanerisdirty.
8.Theseatswitchisnotfunctioning properly.
9.Theelectricalconnectionsare corroded,loose,ordamaged.
10.Therelayorswitchiswornor damaged.
11.Thesparkplugisfouledorimproperly gapped.
12.Thespark-plugwireisnotconnected.
3.Movethemotion-controllevers outwardtotheNEUTRAL-LOCKposition.
4.Sitontheoperator’sseat.
5.Chargethebattery.
6.Checktheelectricalconnectionsfor goodcontact.
8.ContactanAuthorizedServiceDealer.
4.Besurethatthethrottlecontrolis midwaybetweentheslowandfast positions.
6.ContactanAuthorizedServiceDealer.
7.Cleanorreplacetheair-cleaner element.
8.Checktheseat-switchindicator. Replacetheseatifnecessary .
9.Checktheelectricalconnections forgoodcontact.Cleanthe connectorterminalsthoroughlywith electrical-contactcleaner,apply dielectricgrease,andmakethe appropriateconnections.
10.ContactanAuthorizedServiceDealer.
11.Adjustorreplacethesparkplug.
12.Checkthespark-plugwireconnection.
Theenginelosespower.
Theengineoverheats.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theaircleanerisdirty.
3.Theoillevelinthecrankcaseislow.3.Addoiltothecrankcase.
4.Thecoolingnsandtheairpassages abovetheengineareplugged.
5.Theventholeinthefuelcapisplugged.5.Cleanorreplacethefuelcap.
6.Thereisdirtinthefuellter.6.Replacethefuellter.
7.Thereisdirt,water,orstalefuelinthe fuelsystem.
1.Theengineloadisexcessive.1.Reducethegroundspeed.
2.Theoillevelinthecrankcaseislow.2.Addoiltothecrankcase.
3.
Thecoolingnsandairpassages undertheengine-blowerhousingare plugged.
4.Theaircleanerisdirty.
5.
Dirt,water ,orstalefuelisinthefuel system.
2.Cleantheair-cleanerelement.
4.Removetheobstructionfromthe coolingnsandtheairpassages.
7.ContactanAuthorizedServiceDealer.
3.Removetheobstructionfromthe coolingnsandairpassages.
4.Cleanorreplacetheair-cleaner element.
5.ContactanAuthorizedServiceDealer
75
Page 76
Problem
PossibleCauseCorrectiveAction
Themachinepullstotheleftorright(with leversfullyforward)
Themachinedoesnotdrive.
Themachinevibratesabnormally .
Thecuttingheightisuneven.
1.Thetrackingneedsadjustment1.Adjustthetracking.
2.Thetirepressureinthedrivetiresis notcorrect.
1.Thebypassvalvesarenotclosedtight.1.Tightenthebypassvalves.
2.Thepumpbeltisworn,loose,or broken.
3.Thepumpbeltisoffapulley.3.Changethebelt.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
5.Thehydraulicuidlevelislowortoo hot.
1.Thecuttingblade(s)is/arebentor unbalanced.
2.Theblademountingboltisloose.2.Tightentheblademountingbolt.
3.Theenginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Theenginepulley ,idlerpulley,orblade pulleyisloose.
5.Theenginepulleyisdamaged.
6.Thebladespindleisbent.
7.Themotormountislooseorworn.
1.Theblade(s)isnotsharp.1.Sharpentheblade(s).
2.Acuttingblade(s)is/arebent.2.Installanewcuttingblade(s).
3.Themowerisnotlevel.
4.Ananti-scalproller(ifapplicable)isnot setcorrectly .
5.Theundersideofthemowerdeckis dirty.
6.Thetirepressureisincorrect.6.Adjustthetirepressure.
7.Abladespindleisbent.
2.Adjustthetirepressureinthedrive tires.
2.Changethebelt.
5.Addhydraulicuidtothereservoirsor letitcooldown.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
3.Levelthemowerfromside-to-sideand front-to-rear.
4.Adjusttheanti-scalpwheelheight.
5.Cleantheundersideofthemower deck.
7.ContactanAuthorizedServiceDealer.
Thebladesdonotrotate.
Theclutchdoesnotengage.
1.Themowerdeckbeltisdamaged, worn,loose,orbroken.
2.Themowerdeckbeltisoffthepulley.
3.Thepumpdrivebeltisworn,loose,or broken.
4.Theidlerspringisbrokenormissing.4.Replacethespring.
1.Thefuseisblown.
2.Thereislowvoltagesupplyatthe clutch.
Thecoilisdamaged.
3.
4.Thereisinadequatecurrentsupply.4.Repairorreplacetheclutchlead
5.
Therotor/armatureairgapistoolarge.
1.Installanewdeckbelt.
2.Installthemowerbeltonthedeck pulleyandchecktheidlerpulley,idler arm,andspringforcorrectposition andfunction.
3.Checkthebelttensionorinstallanew belt.
1.Replacethefuse.Checkthecoil resistance,batterycharge,charging system,andwiringconnections,and replacecomponentsifnecessary.
2.Checkthecoilresistance,battery charge,chargingsystem,andwiring connectionsandreplacepartsif necessary.
Replacetheclutch.
3.
wireorelectricalsystem.Cleanthe connectorcontacts.
5.Removetheshimorreplacetheclutch.
76
Page 77
Schematics
ElectricalSchematic—KawasakiEngines(Rev.A)
77
g009180
Page 78
ElectricalSchematic—KohlerEngines(Rev.A)
78
g020788
Page 79
CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:
WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.
Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all
AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally ,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.
.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.
•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies
makingsimilarproductsmayhavenosuchrequirement.
•TheenforcementofProp65isinconsistent.
•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora
productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromToroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,TorohaselectedtoprovidetheProp65warnings.Moreover ,ifTorodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.
RevA
Page 80
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