Toro 74975, 74977 Operator's Manual

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FormNo.3366-112RevA
g013435
ZMaster
with60inTURBOFORCE
®
G3RidingMower
®
SideDischarge
Mower
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.Toro.com.OriginalInstructions(EN)
Page 2
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThissparkignitionsystemcomplieswithCanadian ICES-002
Becauseinsomeareastherearelocal,state,orfederal regulationsrequiringthatasparkarresterbeusedon theengineofthismachine,asparkarresterisavailable asanoption.Ifyourequireasparkarrestor,contact yourAuthorizedT oroDealer.
GenuineTorosparkarrestersareapprovedbytheUSDA ForestryService.
Note:ItisaviolationofCaliforniaPublicResource CodeSection4442touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped,and maintainedforthepreventionofre.Otherstatesor federalareasmayhavesimilarlaws.
Theenclosed
Engine Owner’ s Man ual
forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
issupplied
DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol
Figure2),whichsignalsahazardthatmaycauseserious
( injuryordeathifyoudonotfollowtherecommended precautions.
Introduction
Thisrotary-blade,ridinglawnmowerisintendedtobe usedbyresidentialhomeownersorprofessional,hired operators.Itisdesignedprimarilyforcuttinggrasson well-maintainedlawnsonresidentialorcommercial properties.Itisnotdesignedforcuttingbrushorfor agriculturaluses.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely .
YoumaycontactTorodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService
©2010—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
SlopeIndicator.....................................................6
Contactusatwww.T oro.com.
2
PrintedintheUSA.
AllRightsReserved
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SafetyandInstructionalDecals.............................7
ProductOverview......................................................12
Controls.............................................................12
Specications.....................................................13
Operation...................................................................14
AddingFuel.......................................................14
CheckingtheEngineOilLevel............................16
BreakingInaNewMachine................................16
UsingtheRolloverProtectionSystem
(ROPS)..........................................................17
ThinkSafetyFirst...............................................17
OperatingtheParkingBrake...............................18
OperatingtheMowerBladeControlSwitch
(PTO)............................................................19
OperatingtheThrottle.......................................19
OperatingtheIgnitionSwitch.............................19
StartingandStoppingtheEngine........................20
TheSafetyInterlockSystem................................21
DrivingForwardorBackward.............................22
StoppingtheMachine.........................................23
AdjustingtheHeightofCut................................23
AdjustingtheAnti-ScalpRollers.........................24
AdjustingtheFlowBafeCamLocks..................25
PositioningtheFlowBafe.................................25
PositioningtheSeat............................................26
UnlatchingtheSeat.............................................27
UsingtheDriveWheelReleaseValves.................27
UsingtheSideDischarge....................................27
TransportingMachines.......................................27
LoadingMachines..............................................28
OperatingTips...................................................29
Maintenance...............................................................31
RecommendedMaintenanceSchedule(s)................31
Lubrication.............................................................32
GreasingandLubrication...................................32
WheretoGreasetheMower...............................32
LubricateCasterWheelHubs.............................33
EngineMaintenance...............................................34
ServicingtheAirCleaner....................................34
ServicingtheEngineOil.....................................35
ServicingtheSparkPlug.....................................38
CheckSparkArrester(ifequipped)......................39
FuelSystemMaintenance.......................................40
InspectingtheLPGSystem.................................40
ElectricalSystemMaintenance................................41
ServicingtheBattery...........................................41
ServicingtheFuses.............................................43
DriveSystemMaintenance.....................................43
CheckingtheSeatBelt........................................43
CheckingtheRolloverProtectionSystem
(ROPS)Knobs...............................................43
AdjustingtheTracking........................................44
CheckingtheTirePressure.................................44
CheckingtheWheelHubSlottedNut..................45
AdjustingtheCasterPivotBearing......................45
UsingtheClutchShim........................................45
CoolingSystemMaintenance..................................47
CleaningtheEngineScreenandEngineOil
Cooler............................................................47
CleaningtheEngineCoolingFinsand
Shrouds..........................................................47
CheckandCleantheHydraulicUnit
Shrouds..........................................................48
BrakeMaintenance.................................................49
AdjustingtheParkingBrake................................49
BeltMaintenance....................................................50
InspectingtheBelts............................................50
ReplacingtheMowerBelt...................................50
ReplacingtheHydraulicPumpDrive
Belt................................................................51
ControlsSystemMaintenance.................................52
AdjustingtheControlHandlePosition................52
AdjustingtheMotionControlLinkage................52
AdjustingtheMotionControlDamper...............53
AdjustingtheMotionControlNeutralLock
Pivot..............................................................53
HydraulicSystemMaintenance...............................54
ServicingtheHydraulicSystem...........................54
MowerDeckMaintenance......................................56
LevelingtheMowerDeck...................................56
ServicingtheCuttingBlades...............................58
RemovingtheMowerDeck................................61
ReplacingtheGrassDeector.............................62
Cleaning.................................................................63
CleaningUndertheMower.................................63
WasteDisposal...................................................63
Storage.......................................................................63
CleaningandStorage..........................................63
Troubleshooting.........................................................65
Schematics.................................................................67
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Safety
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol,whichmeans CAUTION,WARNING,orDANGER-“personal safetyinstruction."Failuretocomplywiththe instructionmayresultinpersonalinjuryordeath.
Thisproductiscapableofamputatinghandsand feetandthrowingobjects.Alwaysfollowallsafety instructionstoavoidseriousinjuryordeath.
Thisproductisdesignedforcuttingandrecyclinggrass or,whenequippedwithagrassbagger,forcatching cutgrass.Anyuseforpurposesotherthanthesecould provedangeroustouserandbystanders.
SafeOperatingPractices
ThefollowinginstructionsarefromANSIstandard B71.4-2004.
Training
ReadtheOperator’sManualandothertraining material.Iftheoperator(s)ormechanic(s)cannot readEnglishitistheowner’sresponsibilitytoexplain thismaterialtothem.
Becomefamiliarwiththesafeoperationofthe equipment,operatorcontrols,andsafetysigns.
Alloperatorsandmechanicsshouldbetrained.The ownerisresponsiblefortrainingtheusers.
Neverletchildrenoruntrainedpeopleoperateor servicetheequipment.Localregulationsmayrestrict theageoftheoperator.
Theowner/usercanpreventandisresponsiblefor accidentsorinjuriesoccurringtohimselforherself, otherpeopleorproperty.
Preparation
Evaluatetheterraintodeterminewhataccessories andattachmentsareneededtoproperlyand safelyperformthejob.Onlyuseaccessoriesand attachmentsapprovedbythemanufacturer.
Wearappropriateclothingincludinghardhat,safety glassesandhearingprotection.Longhair,loose clothingorjewelrymaygettangledinmovingparts.
Inspecttheareawheretheequipmentistobeused andremoveallobjectssuchasrocks,toysandwire whichcanbethrownbythemachine.
UseextracarewhenhandlingLPGfuel(liqueed petroleumgas).Thevaporsareammableand explosive.
Useonlyanapprovedtank –Neverrefuelthemachineindoors. –LPGbecomesammablewhenitismixedwith
air.
Neverremovethetankwithenginerunning.
Allowenginetocoolbeforerefueling.Donot smoke.
Checkthatoperator’spresencecontrols,safety switchesandshieldsareattachedandfunctioning properly.Donotoperateunlesstheyarefunctioning properly.
Operation
Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
Neverrunanengineinanenclosedarea.
Onlyoperateingoodlight,keepingawayfromholes andhiddenhazards.
Besurealldrivesareinneutralandparkingbrakeis engagedbeforestartingengine.Starttheengineonly fromtheoperator’sposition.Useseatbelts.
Neverraisemowerwiththebladesrunning.
NeveroperatewithoutthePTOshield,orother guardssecurelyinplace.Besureallinterlocksare attached,adjustedproperly ,andfunctioningproperly.
Neveroperatewiththedischargedeectorraised, removedoraltered,unlessusingagrasscatcher.
Donotchangetheenginegovernorsettingor overspeedtheengine.
Stoponlevelground,lowerimplements,disengage drives,engageparkingbrake,shutoffenginebefore leavingtheoperator’spositionforanyreason includingemptyingthecatchersoruncloggingthe chute.
Stopequipmentandinspectbladesafterstriking objectsorifanabnormalvibrationoccurs.Make necessaryrepairsbeforeresumingoperations.
Keephandsandfeetawayfromthecuttingunits.
Nevercarrypassengersandkeeppetsandbystanders away.
Bealert,slowdownandusecautionwhenmaking turns.Lookbehindandtothesidebeforechanging directions.
Slowdownandusecautionwhencrossingroadsand sidewalks.Stopbladesifnotmowing.
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Beawareofthemowerdischargedirectionanddo notpointitatanyone.
Donotoperatethemowerundertheinuenceof alcoholordrugs.
Useextremecarewhenloadingorunloadingthe machineintoatrailerortruck.
Usecarewhenapproachingblindcorners,shrubs, trees,orotherobjectsthatmayobscurevision.
SlopeOperation
Donotmowslopesgreaterthan15degrees.
Donotmowneardrop-offs,ditches,steepbanks orwater.Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury,death ordrowning.
Donotmowslopeswhengrassiswet.Slippery conditionsreducetractionandcouldcausesliding andlossofcontrol.
Donotmakesuddenturnsorrapidspeedchanges.
Useawalkbehindmowerand/orahandtrimmer neardrop-offs,ditches,steepbanksorwater.
Reducespeedanduseextremecautiononslopes.
Removeormarkobstaclessuchasrocks,treelimbs, etc.fromthemowingarea.Tallgrasscanhide obstacles.
Watchforditches,holes,rocks,dips,andrisesthat changetheoperatingangle,asroughterraincould overturnthemachine.
Avoidsuddenstartswhenmowinguphillbecause themowermaytipbackwards.
Beawarethatoperatingonwetgrass,acrosssteep slopes,ordownhillmaycausethemowertolose traction.Lossoftractiontothedrivewheelsmay resultinslidingandalossofbrakingandsteering.
Alwaysavoidsuddenstartingorstoppingona slope.Iftireslosetraction,disengagethebladesand proceedslowlyofftheslope.
Followthemanufacturer’srecommendationsfor wheelweightsorcounterweightstoimprovestability.
Useextremecarewithgrasscatchersorother attachments.Thesecanchangethestabilityofthe machineandcauselossofcontrol.
UsingtheRolloverProtectionSystem (ROPS)
Keeptherollbarintheraisedandlockedposition andusetheseatbeltwhenoperatingthemachine.
Becertainthattheseatbeltcanbereleasedquickly intheeventofanemergency.
Beawarethereisnorolloverprotectionwhenthe rollbarisdown.
Checktheareatobemowedandneverfoldthe ROPSinareaswherethereareslopes,dropoffsor water.
Lowertherollbaronlywhenabsolutelynecessary. Donotweartheseatbeltwiththerollbarfolded down.
Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)beforedriving underanyobjectsanddonotcontactthem.
Maintenanceandstorage
Disengagedrives,lowerimplement,setparking brake,stopengineandremovekeyordisconnect sparkplugwire.Waitforallmovementtostop beforeadjusting,cleaningorrepairing.
Cleangrassanddebrisfromcuttingunits,drives, mufers,andenginetohelppreventres.Cleanup oilorfuelspillage.
Letenginecoolbeforestoringanddonotstorenear ame.
Shutofffuelwhilestoringortransporting.Donot storefuelnearamesordrainindoors.
Parkmachineonlevelground.Neverallowuntrained personneltoservicemachine.
Usejackstandstosupportcomponentswhen required.
Carefullyreleasepressurefromcomponentswith storedenergy.
Disconnectbatteryorremovesparkplugwirebefore makinganyrepairs.Disconnectthenegativeterminal rstandthepositivelast.Reconnectpositiverst andnegativelast.
Usecarewhencheckingblades.Wraptheblade(s)or weargloves,andusecautionwhenservicingthem. Onlyreplacedamagedblades;neverstraightenor weldthem.
Keephandsandfeetawayfrommovingparts.If possible,donotmakeadjustmentswiththeengine running.
Chargebatteriesinanopenwellventilatedarea, awayfromsparkandames.Unplugchargerbefore connectingordisconnectingfrombattery.Wear protectiveclothinganduseinsulatedtools.
Keepallpartsingoodworkingconditionandall hardwaretightened.Replaceallwornordamaged decals.
UseonlyToroapprovedattachments.Warrantymay bevoidedifusedwithunapprovedattachments.
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SlopeIndicator
G011841
Figure3
Thispagemaybecopiedforpersonaluse.
1.Themaximumslopeyoucansafelyoperatethemachineonis15degrees.Usetheslopecharttodeterminethedegreeofslope ofhillsbeforeoperating.Donotoperatethismachineonaslopegreaterthan15degrees.Foldalongtheappropriateline tomatchtherecommendedslope.
2.Alignthisedgewithaverticalsurface,atree,building,fencepole,etc.
3.Exampleofhowtocompareslopewithfoldededge.
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SafetyandInstructional Decals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
68-8340
1-403005
98-5954
103-2076
54-9220
58-6520
1.Grease
105-7798
66-1340
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109-7232
1.Fast3.Neutral
2.Slow
4.Reverse
107-2102
107-2112
109-7929
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1.Main,25A
2.PTO,10A
114-4466
3.Charge,25A
4.Auxiliary,15A
109-9875
1.Greasepulleysandspindles
2.Maintenanceinterval—50hours
116-0157
110-2067
115-7445
110-2068
1.ReadtheOperator’sManual.
116-0205
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1.Locked2.Unlocked
116-0211
116-0752
116-3446
1.Battery4.Parkingbrake
2.Hourmeter5.Neutral
3.PTO6.Operatorpresenceswitch
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator’s
Manual.
6.Keepbystandersasafe distancefromthebattery.
7.Weareyeprotection; explosivegasescan causeblindnessandother injuries
8.Batteryacidcancause blindnessorsevereburns.
withwaterandgetmedical helpfast.
10.Containslead;donot discard.
116-1714
1.Indicatesthebladeisidentiedasapartfromtheoriginal machinemanufacturer.
Manufacturer’sMark
116-2643
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119-4233
1.PowerT ake-off(PTO)3.Continuousvariable
2.Fast
setting
4.Slow
109-9906
109-7069
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ProductOverview
g013436
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1
8
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g013663
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25
10
15
1
2
3
4
5
Figure4
1.Height-of-cutdecklift pedal
2.Transportlock7.Rollbar
3.Parkingbrakelever8.Motioncontrollevers
4.Controls9.Casterwheel
5.Seatbelt
6.Fueltank
10.Mowerdeck
HourMeter
Thehourmeterrecordsthenumberofhourstheengine hasoperated.Itoperateswhentheengineisrunning. Usethesetimesforschedulingregularmaintenance
Figure6).
(
FuelGauge
LocatedontheLPGfueltank.
ThisgaugemonitorstheamountofliquidLPGinthe fueltank.
SafetyPressureReliefValve
LocatedontheLPGfueltank.
Thesafetypressurereliefvalverelievestheexcess pressureintheLPGtank.
Important:Thisvalvehasaprotectiveplasticcap thatshouldNEVERberemoved.Ifthecapis damagedormissing,contacttrainedandqualied personnelimmediately.
LPGCylinderBrackets
Thebracketsarelocatedontheenginedeck.
TheLPGcylinderbracketsareusedtofastenthe removableLPGtanktothemower.
SafetyInterlockIndicators
Controls
Becomefamiliarwithallthecontrolsbeforeyoustartthe engineandoperatethemachine(Figure4andFigure5).
Therearesymbolsonthehourmeterandtheindicate withablacktrianglethattheinterlockcomponentisin thecorrectposition(Figure6).
BatteryIndicatorLight
IftheignitionkeyisturnedtotheOnpositionforafew
1.PTOSwitch
2.Throttlecontrol5.Fuses
3.Hourmeter/Safety interlockdisplay
Figure5
4.Ignitionswitch
seconds,thebatteryvoltagewillbedisplayedinthearea wherethehoursarenormallydisplayed.
Thebatterylightturnsonwhentheignitionisturned onandwhenthechargeisbelowthecorrectoperating
Figure6).
level(
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g013439
1
2
3
Figure6
1.Batterylight
2.Hourmeter
3.Safetyinterlocksymbols
ThrottleControl
ThethrottlecontrolisvariablebetweenFastandSlow.
enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.T oro.comforalistofallapprovedattachments andaccessories.
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
Width:
60inchDeck72inchDeck
WithoutDeck
DeectorUp61.73inches(156.8
DeectorDown75.67inches(192.2
53.0inches(134.6 cm)
cm)
cm)
59.1inches(150.1 cm)
73.61inches(187 cm)
87.55inches(222.4 cm)
BladeControlSwitch(PTO)
Thebladecontrolswitch(PTO)isusedtoengagethe electricclutchanddrivethemowerblades.Pullthe switchuptoengagethebladesandrelease.Todisengage theblades,pushthebladecontrolswitch(PTO)down ormoveamotioncontrolleverintotheneutrallock position.
IgnitionSwitch
Thisswitchisusedtostartthemowerengineandhas threepositions:Start,RunandOff.
MotionControlLevers
Themotioncontrolleversareusedtodrivethemachine forward,reverse,andturneitherdirection.
NeutralLockPosition
Theneutrallockpositionisusedwiththesafetyinterlock systemtoengageandtodetermineneutralposition.
FuelShut-offValve
Closethefuelshut-offvalveonthecylindertankwhen transportingorstoringthemower.
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto
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Length:
RollBar-Up
RollBar-Down
60inchDeck72inchDeck
83.1inches(211.1 cm)
84.8inches(215.4 cm)
86.1inches(218.7 cm)
87.8inches(223.0 cm)
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
AddingFuel
Height:
RollBar-UpRollBar-Down
70.5inches(179.1cm)46.8inches(1 18.9cm)
Weight:
60inchDeck72inchDeck
29HPKawasaki Units
1255lb(569kg)1350lb(612kg)
TankTypeandRelling
Note:TheLPGtankusedonthismowerisaspecial tankwithinternalbafesdesignedforthisapplication.
HorizontalTankSpecications:
TankMaterial:Aluminum
Capacity:43.5lb
Disconnectcoupling:LefthandACMEthreaded
FuelWithdrawal:Vapor
FuelShut-OffValve:Rotateclockwisetoclose.
Typeoffuel:HD5gradepropane
WhatisLPG?LPGstandsforliqueedpetroleumgas andismorecommonlycalledpropane.LPGisaliquid fuelthatisstoredinatankunderpressure.Beforethe liquidleavesthetank,itisconvertedintoavapor.Since LPGisstoredasbothliquidandgas,itmayleakfrom jointsorconnectionsthatarenotsealedproperly.LPG becomesammablewhenitismixedwithair.
TheLPGinformationinthisOperator’smanualis providedonlyasaguide.ConsulttheNFPA58: LiqueedPetroleumGasCode,2008Editionfor additionalsafetyinformation.ThisNationalFire ProtectionAssociation(NFPA)codepertainstothe handling,storing,transporting,andusageofLPG.
Typeoffuel:HD5gradepropane
CAUTION
Undernocircumstancesshouldpropanetanks lledbeyond80%capacitybeusedinservice.
Theuseofoverlledtanksmayresultintherelease ofhighlyconcentratedandextremelyammable liquidpropane.RefertotheSafetysection.
Newtanksmustbeproperlylledbytrainedand qualiedpersonnel.
OnlyusetanksrecommendedbyToro.Failureto dosowillresultinimproperoperationofthefuel system.
Note:Useofa“forklift”typeliquidwithdrawaltank willresultinicingorfreezingoftheLPGregulatorand preventtheenginefromoperating.Thismayalsoresult inpermanentfuelsystemdamageandthereleaseof highlyammablepropaneliquidorvapor.
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DANGER
DANGER
LPGfuelisextremelyammableandvaporsare explosive.
AreorexplosionfromLPGfuelcanburnyou, others,andcausepropertydamage.
Neversmokearoundtank(s)andstayaway fromanopenameorwherefumesmaybe ignitedbyaspark.
Extinguishallsourcesofsparkoramewhen approachingLPGtanksormowers.The hazardincreasesforenclosedtrailersorstorage locationswherevaporleakagemayoccurand collect.
LPGisheavierthanairandmayaccumulatein lowlyingareas,suchasditches,drains,orpits.
LPGtank(s)shouldbelledbytrainedand qualiedpersonnelONLY .
Nevertamperwithorrepairthetank(s);contact trainedandqualiedpersonnel.
DoNotchangethetank(s)whentheengineis running.
Beforedisconnectingthehose(s),purgeall LPGvaporsfromthesystem,byclosingthefuel valve(s)onALLtanksandallowingtheengine torununtilitstops.
Storethetank(s)awayfromheat,sparks,or openames.
DoNotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
DANGER
LPGvaporsandliquidescapingfromthetankmay causeseriousinjuryordeath.V aporsorliquidmay causesuffocation,freezingoftissue,orfrostbite.
Storeandservicethemowerinawellventilated area.
AnapprovedLPGdetectorinstalledintrailers andstorageareasisrecommended.
LPGisheavierthanairandmayaccumulatein lowlyingareas,suchasditches,drains,orpits.
Avoidbreathingofvapors.
Keepawayfromventvalve.
Keepawayfromeyesandskin.
Contacttrainedandqualiedpersonneliftank showssignsoffrostedareas,makesahissing sound,oremitsafoulodor.
Obtainimmediatemedicalattentionifcontact occurswithvaporsorliquid.
LPGfuelisextremelyammableandvaporsare explosive.
Incaseofretakethefollowingsteps:
1.Ifyoucansafelydoso,stoptheowofgas asquicklyaspossible.Neverputoutame unlessgascanbeshutoff.
2.NotifytheFireDepartmentandclear immediateareaofallpeople.
3.Whengasowisstopped,putoutthere. Usuallywhenowofgasiscutoff,rewill automaticallystop.
4.Ifgasowcannotbeimmediatelystopped, directwaterontankstokeepthemcool,but DoNotputoutre.
Storagelocationsandtrailersshouldbe equippedwithatleastoneapprovedportable reextinguisherhavingaminimumcapacityof 18lb(8.2kg)drychemicalwithaB:Crating. DoNotuseCarbonTetrachlorideextinguishers (Pyreneetc.).
ChangingtheLPGTank
ChangetheLPGtankoutdoorsinawellventilatedarea.
Important:Onlyhandtightentankconnection tting.Overtighteningbytheuseoftoolsmay causedamage.Ifhandtighteningdoesnotstop aleak,contacttrainedandqualiedpersonnel immediately.
1.Stopthemachineonlevelground,disengagethe bladecontrolswitch(PTO),movethemotion controlleverstotheneutrallockedpositionandset theparkingbrake.
2.Waitforallmovingpartsforthemowerdeckto stopbeforeleavingtheoperatingposition.
3.Withtheenginerunning,closethefuelvalveonthe tank.
4.Runtheengineuntilitstops.Thispurgesallvapors fromthehose.
5.Removethekey.
6.CarefullydisconnecttheLPGfuelhose.
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g013437
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2
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Figure7
G013669
1.LPGfuelhoseconnection tting
2.Tankvalve
3.Fuelgauge
7.Unlatchthecylinderbracketsandremovethetank.
Figure8
1.Cylinderbrackets3.Centerhole
2.Mountingpin
Important:V alvesandgaugesmaynot functionproperlyiftheLPGtankisnot installedcorrectly.
WARNING
Fuelsystemcomponentsareunderhigh pressure.Theuseofdamagedorimproper componentscancausesystemfailure,fuel leakage,andpossibleexplosion,whichmay resultinseriousinjuryordeath.
DoNotattempttorepairormodifythe valves,ttings,orothertankcomponents.
ONLYusetheToroapprovedLPGtank, ttings,andhosesthatweredesignedfor yourmower.
12.Latchthecylinderbracketsandmakesurethetank issecurelyfastenedtothemower.
13.Carefullyconnectthefuelhose.Makesurethehose isnotkinked.
14.Slowlyopenthefuelvalvetoequalizethepressurein thetank.Ifthefuelvalveisopenedtooquickly,the pressurereliefvalveisequippedwithabackpressure checkvalvethatwillshutoffthefuelsupply.Ifthis happens,closethefuelvalvecompletelyandwait veseconds.Slowlyopenthefuelvalve.
15.CheckforleaksasdescribedintheInspection section.
8.Inspectthelledtankvalveandttingopeningsfor dirt,debris,ordamage.
CheckingtheEngineOilLevel
9.Inspectthetankhoseconnectionttingfor damagedormissingo-rings.
10.Makesurethereplacementtanktypeandsizematch thetankspecicationdecal.
11.Alignthecenterholeoverthemountingpinthat pointsstraightuponthemowerasshownin Figure8.
Beforeyoustarttheengineandusethemachine,check theoillevelintheenginecrankcase;refertoChecking theEngineOilLevel.
BreakingInaNewMachine
Newenginestaketimetodevelopfullpower.Mower decksanddrivesystemshavehigherfrictionwhennew, placingadditionalloadontheengine.Allow40to50 hoursofbreak-intimefornewmachinestodevelopfull powerandbestperformance.
16
Page 17
UsingtheRolloverProtection
g013441
2 1
3
4
System(ROPS)
WARNING
Toavoidinjuryordeathfromrollover:keepthe rollbarintheraisedlockedpositionandusethe seatbelt.
Ensurethattherearpartoftheseatissecuredwith theseatlatch.
WARNING
Thereisnorolloverprotectionwhentherollbar isinthedownposition.
Lowertherollbaronlywhenabsolutely necessary.
Donotweartheseatbeltwhentherollbaris inthedownposition.
Driveslowlyandcarefully.
Raisetherollbarassoonasclearancepermits.
Checkcarefullyforoverheadclearances(i.e. branches,doorways,electricalwires)before drivingunderanyobjectsanddonotcontact them.
Important:Lowertherollbaronlywhen absolutelynecessary .
Important:Ensurethattherearpartoftheseatis securedwiththeseatlatch.
1.Tolowertherollbar,applyforwardpressuretothe upperpartoftherollbar.
2.Pullbothknobsoutandrotatethem90°sotheyare notengaged(
3.Lowertherollbartothedownposition(
Figure9).
Figure9).
Figure9
1.ROPSknob
2.PullROPSknoboutand rotate90degrees
3.Rollbarintheupright position
4.Rollbarinthefolded position
4.Toraisetherollbar,raisetherollbartotheoperate position,rotatetheknobssotheymovepartially intothegrooves(
Figure9).
5.Raisetherollbartothefulluprightpositionwhile pushingontheupperrollbarandthepinswillsnap intopositionwhentheholesalignwiththepins
Figure9).Pushontherollbarandensurethat
( bothpinsareengaged.
Important:Alwaysusetheseatbeltwiththe rollbarintheraisedposition.
ThinkSafetyFirst
Pleasereadallsafetyinstructionsandsymbolsinthe safetysection.Knowingthisinformationcouldhelp youorbystandersavoidinjury.
17
Page 18
DANGER
G009027
1
2
G008960
1
2
CAUTION
Operatingonwetgrassorsteepslopescancause slidingandlossofcontrol.
Wheelsdroppingoveredgescancauserollovers, whichmayresultinseriousinjury,deathor drowning.
Thereisnorolloverprotectionwhentherollbar isdown.
Alwayskeeptherollbarintheraisedandlocked positionandusetheseatbelt.
Readandfollowtherolloverprotectioninstructions andwarnings.
Toavoidlossofcontrolandpossibilityofrollover:
Donotoperateneardrop-offsornearwater.
Donotoperateonslopesgreaterthan 15degrees.
Reducespeedanduseextremecautionon slopes.
Avoidsuddenturnsorrapidspeedchanges.
Thismachineproducessoundlevelsinexcessof 85dBAattheoperatorsearandcancausehearing lossthroughextendedperiodsofexposure.
Wearhearingprotectionwhenoperatingthis machine.
Theuseofprotectiveequipmentforeyes,ears,feetand headisrecommended.
Figure11
1.Wearsafetyglasses
2.Wearhearingprotection
OperatingtheParkingBrake
Alwayssettheparkingbrakewhenyoustopthe machineorleaveitunattended.
1.SafeZone-usethe ZMasterhereonslopes lessthan15degreesor atareas.
2.DangerZone-useawalk behindmowerand/ora handtrimmeronslopes greaterthan15degrees, neardrop-offsandwater.
SettingtheParkingBrake
WARNING
Parkingbrakemaynotholdmachineparkedona slopeandcouldcausepersonalinjuryorproperty damage.
Donotparkonslopesunlesswheelsarechocked orblocked
Figure10
3.Water
Figure12
ReleasingtheParkingBrake
Pushinthereleasebuttonbeforepushingdown.
18
Page 19
G008944
1
2
3
G008945
DisengagingtheBladeControlSwitch
G009174
G008946
(PTO)
Figure15
OperatingtheThrottle
Figure13
OperatingtheMowerBlade ControlSwitch(PTO)
Thebladecontrolswitch(PTO)startsandstopsthe mowerbladesandanypoweredattachments.
EngagingtheBladeControlSwitch (PTO)
Note:Engagingthebladecontrolswitch(PTO)with
thethrottlepositionathalforlesswillcauseexcessive weartothedrivebelts.
Figure14
ThethrottlecontrolcanbemovedbetweenFastand Slowpositions(Figure16).
Alwaysusethefastpositionwhenturningonthe mowerdeckwiththebladecontrolswitch(PTO).
Figure16
OperatingtheIgnitionSwitch
1.TurntheignitionkeytotheStartposition (Figure17).Whentheenginesstarts,releasethekey .
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.
19
Page 20
START
RUN
STOP
G008947
Figure17
g013505
6
START
RUN
STOP
G008947
2.Turntheignitionkeytostoptostoptheengine.
StartingandStoppingthe Engine
StartingtheEngine
1.RaisetheROPSupandlockintoplace,sitonthe seatandfastentheseatbelt.
2.Slowlyopenthefuelvalvetoequalizethepressure inthetank.Thefuelvalveislocatedonthetopend oftheLPGtank.Ifthefuelvalveisopenedtoo quickly,thepressurereliefvalveisequippedwith abackpressurecheckvalvethatwillshutoffthe fuelsupply .Ifthishappens,closethefuelvalve completelyandwaitveseconds.Slowlyopenthe fuelvalve.
3.Movethemotioncontrolstoneutrallocked position.
4.Settheparkingbrake;refertoSettingtheParking Brake.
5.Movethebladecontrolswitch(PTO)totheOff position(
Figure18).
Figure18
7.TurntheignitionkeytotheStartposition (Figure17).Whentheenginesstarts,releasethekey .
Important:Donotengagestarterformore than5secondsatatime.Iftheenginefails tostartallowa15secondcool-downperiod betweenattempts.Failuretofollowthese instructionscanburnoutthestartermotor.
Note:Additionalstartingcyclesmayberequired whenstartingtheengineforthersttimeafterthe fuelsystemhasbeenwithoutfuelcompletely.
6.Movethethrottlelevertothe3/4throttleposition betweentheSlowandFastpositions(
Figure18).
Figure19
1.Off3.Start
2.Run
20
Page 21
StoppingtheEngine
6
G013672
1
TheSafetyInterlockSystem
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
Lettheengineidleatslowthrottle(turtle)for60 secondsbeforeturningtheignitionswitchoff.
CAUTION
Ifsafetyinterlockswitchesaredisconnectedor damagedthemachinecouldoperateunexpectedly causingpersonalinjury.
Donottamperwiththeinterlockswitches.
Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.
UnderstandingtheSafetyInterlock System
Thesafetyinterlocksystemisdesignedtopreventthe enginefromstartingunless:
Theparkingbrakeisengaged.
Thebladecontrolswitch(PTO)isdisengaged.
Themotioncontrolleversareintheneutrallocked position
Thesafetyinterlocksystemalsoisdesignedtostopthe enginewhenthetractioncontrolsaremovedfromthe lockedpositionwiththeparkingbrakeengagedorif yourisefromtheseatwhenthePTOisengaged.
Figure20
Important:Makesurethatthefuelshutoffvalveis
closedbeforetransportingorstoringthemachine, asfuelleakagemayoccur.Settheparkingbrake beforetransporting.Makesuretoremovethekey asthefuelpumpmayrunandcausethebattery tolosecharge.
Thehourmeterhassymbolstonotifytheuserwhenthe interlockcomponentisinthecorrectposition.When thecomponentisinthecorrectposition,atrianglewill lightupinthecorrespondingsquare.
Figure21
1.Triangleslightupwhentheinterlockcomponentsareinthe correctposition
TestingtheSafetyInterlockSystem
ServiceInterval:Beforeeachuseordaily
Testthesafetyinterlocksystembeforeyouusethe machineeachtime.Ifthesafetysystemdoesnot operateasdescribedbelow,haveanAuthorizedService Dealerrepairthesafetysystemimmediately.
1.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)toon.Try startingtheengine;theengineshouldnotcrank.
21
Page 22
2.Sittingontheseat,engagetheparkingbrakeand movethebladecontrolswitch(PTO)tooff.Move eithermotioncontrollever(outofneutrallocked position).Trystartingtheengine;theengineshould notcrank.Repeatforothercontrollever.
3.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, releasetheparkingbrake,engagethebladecontrol switch(PTO)andriseslightlyfromtheseat;the engineshouldstop.
4.Sittingontheseat,engagetheparkingbrake,move thebladecontrolswitch(PTO)tooffandmove themotioncontrolleverstoneutrallockposition. Nowstarttheengine.Whiletheengineisrunning, centereithermotioncontrolandmove(forwardor reverse);theengineshouldstop.Repeatforother motioncontrol.
5.Sittingontheseat,disengagetheparkingbrake, movethebladecontrolswitch(PTO)tooffand movethemotioncontrolleverstoneutrallock position.Trystartingtheengine;theengineshould notcrank.
DrivingForwardorBackward
Thethrottlecontrolregulatestheenginespeedas measuredinrpm(revolutionsperminute).Place thethrottlecontrolinthefastpositionforbest performance.Alwaysoperateinthefullthrottle positionwhenmowing.
CAUTION
Machinecanspinveryrapidly.Operatormaylose controlofmachineandcausepersonalinjuryor damagetomachine.
Usecautionwhenmakingturns.
Slowthemachinedownbeforemakingsharp turns.
UsingtheMotionControlLevers
Figure22
1.Motioncontrol lever-neutrallockposition
2.Center,unlockedposition5.Frontofmachine
3.Forward
4.Backward
DrivingForward
Note:Theenginewillkillifthetractioncontrollevers
aremovedwiththeparkingbrakeengaged.
Tostop,pullthemotioncontrolleverstotheneutral position.
1.Releasetheparkingbrake;refertoReleasingthe ParkingBrakeinOperation.
2.Movetheleverstothecenter,unlockedposition.
3.Togoforward,slowlypushthemotioncontrol leversforward(
Figure23).
22
Page 23
G008952
G008953
StoppingtheMachine
Tostopthemachine,movethetractioncontrollevers toneutralandmovetolockedposition,disengagethe powertakeoff(bladecontrolswitch(PTO),andturn theignitionkeytooff.
Settheparkingbrakewhenyouleavethemachine;refer toSettingtheParkingBrakeinOperation.Remember toremovethekeyfromtheignitionswitch.
CAUTION
Childrenorbystandersmaybeinjuredifthey moveorattempttooperatethetractorwhileitis unattended.
Alwaysremovetheignitionkeyandsettheparking brakewhenleavingthemachineunattended,even ifjustforafewminutes.
Figure23
DrivingBackward
1.Movetheleverstothecenter,unlockedposition.
2.Togobackward,slowlypullthemotioncontrol leversrearward(
Figure24).
AdjustingtheHeightofCut
UsingtheTransportLock
Thetransportlockhastwopositionsandisusedwith thedeckliftpedal.Thereisalockpositionandaunlock positionforthetransportposition.Thetransportlock isusedwiththedeckliftpedal.RefertoFigure25
Figure24
23
Page 24
AdjustingtheHeight-of-CutPin
Theheight-of-cutisadjustedfrom1to5-1/2inches (25to140mm)in1/4inch(6mm)incrementsby relocatingtheclevispinintodifferentholelocations.
1.Movethetransportlocktothelockposition.
2.Pushonthedeckliftpedalwithyourfootandraise themowerdecktothetransportposition(also the5-1/2inch(140mm)cuttingheightposition)
Figure26).
(
3.Toadjust,rotatethepin90degreesandremovethe pinfromtheheight-of-cutbracket(Figure26).
4.Selectaholeintheheight-of-cutbracket correspondingtotheheight-of-cutdesiredand, insertthepin(
5.Pushonthedecklift,pullbackonthetransport lock,andslowlylowerthemowerdeck.
Figure26).
Figure25
TransportLockPositions
1.Transportlock3.Unlockposition—doesnot lockthemowerdeckinto transportposition
2.Lockposition—mower
deckwilllockintotransport position
Figure26
1.Deckliftpedal
2.Cutofheightpin
3.Transportlock
AdjustingtheAnti-Scalp Rollers
Wheneveryouchangetheheight-of-cut,itis recommendedtoadjusttheheightoftheanti-scalp rollers.
1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
24
Page 25
Figure27
G008961
1
2
3
4
1.Anti-scalproller4.FlangeNut
2.Spacer
3.Bushing
5.Bolt
AdjustingtheFlowBafeCam Locks
Thisprocedureisapplicableonlytomachineswith theowbafelocks.Certainmodelswillhavenuts andboltsin-placeoftheowbafelocksandcanbe adjustedthesame.
Themowerdischargeowcanbeadjustedfordifferent typesofmowingconditions.Positionthecamlocks andbafetogivethebestqualityofcut.
1.Disengagethebladecontrolswitch(PTO),move themotioncontrolleverstotheneutrallocked positionandsettheparkingbrake.
2.Stoptheengine,removethekey ,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Toadjustthecamlocks,swingtheleverupto loosenthecamlock(Figure30).
4.Adjustthebafeandcamlocksintheslotstothe desireddischargeow.
5.Swingtheleverbackovertotightenthebafeand camlocks(Figure30).
6.Ifthecamlocksdonotlockthebafeintoplace oritistootight,loosentheleverandthenrotate thecamlock.Adjustthecamlockuntilthedesired lockingpressureisachieved.
Figure28
1.Anti-scalproller3.FlangeNut
2.Bushing4.Bolt
Figure29
1.Anti-scalproller4.FlangeNut
2.Spacer
3.Bushing
5.Bolt
Figure30
1.Unlocklever
2.Rotatethecamlockto increaseordecrease lockingpressure
3.Positionthebafe
4.Locklever
PositioningtheFlowBafe
Thefollowingguresareonlyrecommendationsfor use.Adjustmentswillvarybygrasstype,moisture content,andheightofgrass.
Note:Iftheenginepowerdrawsdownandthemower groundspeedisthesame,openupthebafe.
25
Page 26
PositionA
G008962
Allowsincreasedgroundspeedinheavyconditions.
Thisisthefullrearposition.Thesuggesteduseforthis positionisafollows.
Useforshort,lightgrassmowingconditions.
Useindryconditions.
Forsmallergrassclippings.
Propelsgrassclippingsfartherawayfromthe mower.
Figure31
PositionB
Usethispositionwhenbagging.Alwaysalignitwith thebloweropening.
ThispositionissimilartothebenetsoftheToro SFSmower.
Figure33
PositioningtheSeat
Theseatcanmoveforwardandbackward.Positionthe seatwhereyouhavethebestcontrolofthemachine andaremostcomfortable.
Figure32
PositionC
Thisisthefullopenposition.Thesuggestedusefor thispositionisasfollows.
Useintall,densegrassmowingconditions.
Toadjust,movetheleversidewaystounlockseat (Figure34).
Figure34
Useinwetconditions.
Lowerstheenginepowerconsumption.
26
Page 27
UnlatchingtheSeat
g013442
g013443
Figure35
1.Seatlatch2.Seat
UsingtheDriveWheelRelease Valves
1.Verticaltopushthe machine
Figure36
2.Horizontaltorunthe machine
WARNING
Handsmaybecomeentangledintherotatingdrive componentsbelowtheenginedeck,whichcould resultinseriousinjury .
Stoptheengine,removethekey ,andallowall movingpartstostopbeforeaccessingthedrive wheelreleasevalves.
WARNING
Theengineandhydraulicdriveunitscanbecome veryhot.T ouchingahotengineorhydraulicdrive unitscancausesevereburns.
Allowtheengineandhydraulicdriveunitsto coolcompletelybeforeaccessingthedrivewheel releasevalves.
Thedrivewheelreleasevalvesarelocatedinthebackof eachhydraulicdriveunit,undertheseat.
Note:Makesurethereleasevalvesareinthefully horizontalpositionwhenoperatingthemachineor severedamagetothehydraulicsystemcanoccur.
1.DisengagethePTO(bladecontrolswitch)andturn theignitionkeytooff.Movetheleverstoneutral lockedpositionandapplyparkingbrake.Remove thekey .
4.Rotatethereleasevalvelevershorizontallytorun themachine(Figure36).
UsingtheSideDischarge
Themowerhasahingedgrassdeectorthatdisperses clippingstothesideanddowntowardtheturf.
DANGER
Withoutagrassdeector,dischargecover,or completegrasscatcherassemblymountedin place,youandothersareexposedtobladecontact andthrowndebris.Contactwithrotatingmower blade(s)andthrowndebriswillcauseinjuryor death.
Neverremovethegrassdeectorfromthe mowerbecausethegrassdeectorroutes materialdowntowardtheturf.Ifthe grassdeectoriseverdamaged,replaceit immediately.
Neverputyourhandsorfeetunderthemower.
Nevertrytoclearthedischargeareaormower bladesunlessyoumovethepowertakeoff (bladecontrolswitch(PTO)totheoffposition, rotatetheignitionkeytooffandremovethekey.
Makesurethegrassdeectorisinthedown position.
2.Rotatethereleasevalveleversverticallytopushthe machine.Thisallowshydraulicoiltoby-passthe pumpenablingthewheelstoturn(
3.Disengageparkingbrakebeforepushing.
Figure36).
TransportingMachines
Useaheavy-dutytrailerortrucktotransportthe machine.Ensurethatthetrailerortruckhasall necessarybrakes,lighting,andmarkingasrequiredby
27
Page 28
law .Pleasecarefullyreadallthesafetyinstructions.
g013444
Knowingthisinformationcouldhelpyou,yourfamily, petsorbystandersavoidinjury.
Trailersshouldbeequippedwithatleastoneapproved portablereextinguisherhavingaminimumcapacityof 18lb(8.2kg)drychemicalwithaB:Crating.DoNot useCarbonTetrachlorideextinguishers(Pyreneetc.).
WARNING
Drivingonthestreetorroadwaywithoutturn signals,lights,reectivemarkings,oraslow movingvehicleemblemisdangerousandcanlead toaccidentscausingpersonalinjury .
Donotdrivemachineonapublicstreetorroadway .
Besurethefuelvalveisclosedonthetank(s).
PlacespareLPGtank(s)inaDOTapprovedstorage cage.
Transporttanksinanupright,verticaland
securepositiontominimizemovement,tipping, orphysicaldamagerelativetoothertanksorto thestoragecagewhileintransit.
Placetankssothatvalves,ttings,orgauges
areprotectedfromphysicaldamageduring transport.
Placetank(s)inawell-ventilatedtrailer.
DoNotstorethetank(s)ormachinewithtank(s)in anareawherethetemperaturecanriseabove120°F (49°C).Ifthetemperatureexceedsapproximately 160°F(71°C),thetankwillreleasehighlyammable propanevapor.SeePreparationintheSafety Section.
DoNottransportLPGtank(s)inthepassenger spaceofavehicle.
DoNottransportleakingfueltanks.
Trailersmusthaveappropriatemarkingsto transportLPG.
FollowNFPA58andstateandlocalregulationsfor transportingLPG.
Figure37
1.Tractionunittiedownloops
LoadingMachines
Useextremecautionwhenloadingunitsontrailersor trucks.Onefullwidthrampthatiswideenoughto extendbeyondthereartiresisrecommendedinsteadof individualrampsforeachsideoftheunit( Thelowerrearsectionofthetractorframeextends backbetweentherearwheelsandservesasastopfor tippingbackward.Havingafullwidthrampprovides asurfacefortheframememberstocontactifthe unitstartstotipbackward.Ifitisnotpossibletouse onefullwidthramp,useenoughindividualrampsto simulateafullwidthcontinuousramp.
Therampshouldbelongenoughsothattheangles donotexceed15degrees(
Figure38).Asteeperangle maycausemowercomponentstogetcaughtastheunit movesfromramptotrailerortruck.Steeperangles mayalsocausetheunittotipbackward.Ifloadingon ornearaslope,positionthetrailerortrucksoitison thedownsideoftheslopeandtherampextendsupthe slope.Thiswillminimizetherampangle.Thetraileror truckshouldbeaslevelaspossible.
Figure38).
Totransportthemachine:
1.Ifusingatrailer,connectittothetowingvehicle andconnectthesafetychains.
2.Ifapplicable,connectthetrailerbrakes.
3.Loadthemachineontothetrailerortruck.
4.Stoptheengine,removethekey,setthebrake,and closethefuelvalve.
5.Usethemetaltiedownloopsonthemachineto securelyfastenthemachinetothetrailerortruck withstraps,chains,cable,orropes(
Figure37).
Important:DoNotattempttoturntheunitwhile ontheramp;youmaylosecontrolanddriveoff theside.
Avoidsuddenaccelerationwhendrivinguparampand suddendecelerationwhenbackingdownaramp.Both maneuverscancausetheunittotipbackward.
28
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WARNING
Loadingaunitontoatrailerortruckincreasesthe possibilityofbackwardtip-overandcouldcause seriousinjuryordeath.
Useextremecautionwhenoperatingauniton aramp.
EnsuretheROPSisintheuppositionwhile usingtheseatbeltwhenloadingthemachine. EnsuretheROPSwillclearthetopofan enclosedtrailer.
OperatingTips
FastThrottleSetting
Forbestmowingandmaximumaircirculation,operate theengineatthefastthrottleposition.Airisrequired tothoroughlycutgrassclippings,sodonotsetthe height-of-cutsolowastototallysurroundthemower byuncutgrass.Alwaystrytohaveonesideofthe mowerfreefromuncutgrass,whichallowsairtobe drawnintothemower.
Useonlyasingle,fullwidthramp;DoNotuse individualrampsforeachsideoftheunit.
Ifindividualrampsmustbeused,useenough rampstocreateanunbrokenrampsurface widerthantheunit.
Donotexceeda15degreeanglebetweenramp andgroundorbetweenrampandtraileror truck.
Avoidsuddenaccelerationwhiledrivingunitup aramptoavoidtippingbackward.
Avoidsuddendecelerationwhilebackingunit downaramptoavoidtippingbackward.
CuttingaLawnfortheFirstTime
Cutgrassslightlylongerthannormaltoensurethe cuttingheightofthemowerdoesnotscalpanyuneven ground.However,thecuttingheightusedinthepastis generallythebestonetouse.Whencuttinggrasslonger thansixinchestall,youmaywanttocutthelawntwice toensureanacceptablequalityofcut.
Cut1/3oftheGrassBlade
Itisbesttocutonlyabout1/3ofthegrassblade. Cuttingmorethanthatisnotrecommendedunless grassissparse,oritislatefallwhengrassgrowsmore slowly.
MowingDirection
Alternatemowingdirectiontokeepthegrassstanding straight.Thisalsohelpsdisperseclippingswhich enhancesdecompositionandfertilization.
MowatCorrectIntervals
Figure38
1.Trailer3.Notgreaterthan 15degrees
2.Fullwidthramp4.Fullwidthramp—sideview
Normally,moweveryfourdays.Butremember, grassgrowsatdifferentratesatdifferenttimes.So tomaintainthesamecuttingheight,whichisagood practice,mowmoreofteninearlyspring.Asthegrass growthrateslowsinmidsummer,mowlessfrequently . Ifyoucannotmowforanextendedperiod,rstmow atahighcuttingheight;thenmowagaintwodayslater atalowerheightsetting.
CuttingSpeed
Toimprovecutquality ,useaslowergroundspeedin certainconditions.
AvoidCuttingTooLow
Ifthecuttingwidthofthemoweriswiderthanthe moweryoupreviouslyused,raisethecuttingheightto ensurethatuneventurfisnotcuttooshort.
29
Page 30
LongGrass
Ifthegrassiseverallowedtogrowslightlylongerthan normal,orifitcontainsahighdegreeofmoisture,raise thecuttingheighthigherthanusualandcutthegrassat thissetting.Thencutthegrassagainusingthelower, normalsetting.
WhenStopping
Ifthemachine’sforwardmotionmustbestoppedwhile mowing,aclumpofgrassclippingsmaydropontoyour lawn.Toavoidthis,moveontoapreviouslycutarea withthebladesengaged.
KeeptheUndersideoftheMower Clean
Cleanclippingsanddirtfromtheundersideofthe moweraftereachuse.Ifgrassanddirtbuildupinside themower,cuttingqualitywilleventuallybecome unsatisfactory.
BladeMaintenance
Maintainasharpbladethroughoutthecuttingseason becauseasharpbladecutscleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.Checkthecutterblades dailyforsharpness,andforanywearordamage.File downanynicksandsharpenthebladesasnecessary.If abladeisdamagedorworn,replaceitimmediatelywith agenuineTOROreplacementblade.
30
Page 31
Maintenance
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst100hours
Beforeeachuseordaily
Every40hours
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.
•Checkthewheelhubslottednuttorque.
•Checkthetorqueforwheellugnuts.
•Checktheparkbrakeadjustment.
•Checkthesafetysystem.
•Checktheengineoillevel.
•ChecktheLPGtankandcomponents.
•Checktheseatbelt.
•Checktherolloverprotectionsystem(ROPS)knobs.
•Cleantheenginescreenandtheoilcooler.
•Checkandcleanthehydraulicunitshrouds.
•Checkthemowerblades.
•Cleanthemowerdeck.
•ChecktheLPGhoses,regulatorandconnections.
•Greasethemowerdeckspindlesandidlerarm.
•Checksparkarrester(ifequipped).
•Checkthetirepressure.
•Inspectthebeltsforcracksandwear.
•Checkthehydraulicoillevel.
•Lubricatethemowerdeckliftpivots.
•Changetheengineoil.(moreoftenindirtyordustyconditions)
•Check,cleanandregapthesparkplug.
•Checkandcleanenginecoolingnsandshrouds.
Every200hours
Every250hours
Every500hours
Monthly
Yearly
Yearlyorbeforestorage
•Lubricatethebrakehandlepivotwithlightoil.
•Changetheengineoillter.
•Replacetheprimaryairlter.
•Checkthesecondaryairlter.
•ChangethehydraulicltersandhydraulicoilwhenusingMobil®1oil.
•Replacethesecondaryairlter.
•Checkthewheelhubslottednuttorque.
•Checkthetorqueforwheellugnuts.
•Adjustthecasterpivotbearing.
•Checktheparkbrakeadjustment.
•ChangethehydraulicltersandhydraulicoilwhenusingToro®HYPR-OIL™500 hydraulicoil.
•Checkthebattery.
•Greasethepumpbeltidlerarm.
•Greasethefrontcasterpivots(moreoftenindirtyordustyconditions).
•Repackthefrontcasterwheelbearings(moreoftenindirtyordustyconditions).
•Lubricatethecasterwheelhubs
•Paintchippedsurfaces.
•Checkallmaintenanceprocedureslistedabovebeforestorage.
Important:Refertoyourengineoperator’smanualforadditionalmaintenanceprocedures.
31
Page 32
CAUTION
g013445
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionbeforeyoudoanymaintenance.
Lubrication
GreasingandLubrication
Greasemorefrequentlywhenoperatingconditionsare extremelydustyorsandy.
GreaseType:No.2generalpurposelithiumbaseor molybdenumbasegrease
HowtoGrease
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Cleanthegreasettingswitharag.Makesureto scrapeanypaintoffthefrontofthetting(s).
4.Connectagreaseguntothetting.Pumpgrease intothettingsuntilgreasebeginstooozeoutof thebearings.
5.Wipeupanyexcessgrease.
WheretoAddLightOilorSpray Lubrication
ServiceInterval:Every100hours
Every200hours
Brakehandlepivot.
Deckliftpivots.
Figure39
WheretoGreasetheMower
ServiceInterval:Every50hours—Greasethemower
deckspindlesandidlerarm.
Yearly—Greasethepumpbeltidler arm.
Yearly—Greasethefrontcaster pivots(moreoftenindirtyordusty conditions).
Yearly—Repackthefrontcaster wheelbearings(moreoftenindirty ordustyconditions).
Important:Makesurecuttingunitspindlesare fullofgreaseweekly .
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition, andsettheparkingbrake.
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2.Stoptheengine,removethekey,andwaitforall
G009029
movingpartstostopbeforeleavingtheoperating position.
3.Greasethemowerdeckidlerpulleypivotuntilgrease comeoutthebottom(
Figure40).
4.Greasethethreespindlebearingsuntilgreasecomes outthelowerseals(Figure40).
Figure40
Figure42
LubricateCasterWheelHubs
ServiceInterval:Yearly
1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake.
5.Greasethedrivebeltidlerarm(Figure40).
Figure41
6.Removethedustcapandadjustthecasterpivots. Keepthedustcapoffuntilgreasingisdone.Referto AdjustingtheCasterPivotBearinginMaintenance.
7.Removethehexplug.Threadagreasezerkintothe hole.
8.Pumpgreaseintothezerkuntilitoozesoutaround thetopbearing.
Figure43
1.Sealguard2.Spacernutwithwrench ats
2.Removethecasterwheelfromthecasterforks.
3.Removethesealguardsfromthewheelhub.
4.Removeoneofthespacernutsfromtheaxle assemblyinthecasterwheel.Notethatthread lockingadhesivehasbeenappliedtolockthespacer nutstotheaxle.Removetheaxle(withtheother spacernutstillassembledtoit)fromthewheel assembly.
5.Pryoutseals,andinspectbearingsforwearor damageandreplaceifnecessary.
6.Packthebearingswithageneral-purposegrease.
7.Insertonebearing,onenewsealintothewheel.
Note:Thesealsmustbereplaced.
9.Removethegreasezerkinthehole.Installthehex pluganddustcap(Figure42).
8.Iftheaxleassemblyhashadbothspacernuts removed(orbrokenloose),applyathreadlocking
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adhesivetoonespacernutandthreadontotheaxle withthewrenchatsfacingoutward.DoNotthread spacernutallofthewayontotheendoftheaxle. Leaveapproximately1/8inch(3mm)fromthe outersurfaceofthespacernuttotheendoftheaxle insidethenut.
9.Inserttheassemblednutandaxleintothewheelon thesideofthewheelwiththenewsealandbearing.
10.Withtheopenendofthewheelfacingup,ll theareainsidethewheelaroundtheaxlefullof general-purposegrease.
11.Insertthesecondbearingandnewsealintothe wheel.
12.Applyathreadlockingadhesivetothe2ndspacer nutandthreadontotheaxlewiththewrenchats facingoutward.
13.Torquethenutto75-80in-lb(8-9N-m),loosen, thenre-torqueto20-25in-lb(2-3N-m).Makesure axledoesnotextendbeyondeithernut.
14.Reinstallthesealguardsoverthewheelhuband insertwheelintocasterfork.Reinstallcasterbolt andtightennutfully.
Important:Topreventsealandbearingdamage, checkthebearingadjustmentoften.Spinthecaster tire.Thetireshouldnotspinfreely(morethan1or 2revolutions)orhaveanysideplay.Ifthewheel spinsfreely,adjusttorqueonspacernutuntilthere isaslightamountofdrag.Reapplythreadlocking adhesive.
EngineMaintenance
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothingandotherbody partsawaythemuferandotherhotsurfaces.
ServicingtheAirCleaner
ServiceInterval:Every250hours—Replacethe
primaryairlter.
Every250hours—Checkthe secondaryairlter.
Every500hours—Replacethe secondaryairlter.
Note:Servicetheaircleanermorefrequentlyif operatingconditionsareextremelydustyorsandy.
RemovingtheFilters
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Pushdowntoreleasetheretainingclampsontheair cleanerandpulltheaircleanercoveroffoftheair cleanerbody(
Figure44).
4.Cleantheinsideoftheaircleanercoverwith compressedair.
5.Gentlyslidetheprimarylteroutoftheaircleaner
Figure44).Avoidknockingthelterintothe
body( sideofthebody .
6.Removethesecondarylteronlyifyouintendto replaceit.
Important:Neverattempttocleanthe secondarylter.Ifthesecondarylterisdirty, thentheprimarylterisdamagedandyou shouldreplacebothlters.
7.Inspecttheprimarylterfordamagebylookinginto thelterwhileshiningabrightlightontheoutside ofthelter.Holesinthelterwillappearasbright spots.Ifthelterisdamageddiscardit.
34
Page 35
g013445
1
3
4
2
Figure44
1.Aircleanerclamps
2.Aircleanercover
3.Primaryairlter
4.Secondaryairlter
ServicingthePrimaryFilter
1.Donotcleanthepaperlter,replaceit(Figure44).
2.Inspecttheelementfortears,anoilylm,ordamage totherubberseal.
ServicingtheEngineOil
Note:Therearedifferentoilcapacitiesforthe23hp,
27hp,29hp,and34hpengines.Ensurethecorrect capacityisused.
OilType:Detergentoil(APIserviceSG,SH,SJ,orSL)
OilCapacityfor23hpEngines:withalterchange,58
ounces(1.7L);withoutalterchange,51ounces(1.5L)
OilCapacityfor27and29hpEngines:withalter change,77ounces(2.3L);withoutalterchange,70 ounces(2.1L)
OilCapacityfor34hpEngines:withalterchange,64 ounces(1.9L);withoutalterchange,58ounces(1.7L)
Viscosity:Seethetablebelow .
3.Replacethepaperelementifitisdamaged.
ServicingtheSecondaryFilter
Donotcleanthesecondarylter,replaceit.
Important:Neverattempttocleanthesecondary lter.Ifthesecondarylterisdirty,thenthe primarylterisdamagedandyoushouldreplace bothlters.
InstallingtheFilters
Important:Topreventenginedamage,always
operatetheenginewithbothairltersandcover installed.
1.Ifinstallingnewlters,checkeachlterforshipping damage.Donotuseadamagedlter.
2.Ifthesecondarylterisbeingreplaced,carefully slideitintothelterbody(
3.Carefullyslidetheprimarylteroverthesecondary lter(Figure44).Ensurethatitisfullyseatedby pushingontheouterrimofthelterwhileinstalling it.
Important:Donotpressonthesoftinsidearea ofthelter.
4.Installtheaircleanercoverwiththebreathercap downandrotatesotheretainingclampslockthe coverinplace(Figure44).
Figure44).
Figure45
Note:Useofmulti-gradeoils(5W-20,10W -30,or
10W-40)willincreaseoilconsumption.Checktheoil levelmorefrequentlywhenusingthem.
CheckingtheEngineOilLevel
ServiceInterval:Beforeeachuseordaily
Note:Checktheoilwhentheengineiscold.
WARNING
Contactwithhotsurfacesmaycausepersonal injury.
Keephands,feet,face,clothingandotherbody partsawayfromthemuferandotherhotsurfaces.
Important:Donotoverllthecrankcasewithoil becausedamagetotheenginemayresult.Donot runenginewithoilbelowthelowmarkbecausethe enginemaybedamaged.
35
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1.DisengagethePTO,movethemotioncontrollevers
G013447
G008792
1
2
5
6
7
3
9
10
4
8
G013447
G008793
1
2
3
4
4
5
totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(
Figure46).
ChangingtheEngineOil
ServiceInterval:Aftertherst8hours
Every100hours(moreoftenindirty ordustyconditions)
Note:Disposeoftheusedoilatarecyclingcenter.
1.Starttheengineandletitrunveminutes.This warmstheoilsoitdrainsbetter.
2.Parkthemachinesothattherearisslightlylower thanthefronttoensuretheoildrainscompletely.
3.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
4.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position(
Figure47).
Figure46
Figure47
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5.Slowlypourapproximately80%ofthespeciedoil
G008796
2
3
4
5
6
1
G013447
G008748
3/4
1
2
3
4
5
6
intothellertubeandslowlyaddtheadditionaloil tobringittotheFullmark(Figure48).
Figure48
6.Starttheengineanddrivetoaatarea.Checkthe oillevelagain.
ChangingtheEngineOilFilter
ServiceInterval:Every200hours
Note:Changetheengineoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.
1.Draintheoilfromtheengine;refertoChangingthe EngineOil.
2.Changetheengineoillter(
Figure49).
Figure49
Note:Ensuretheoilltergaskettouchestheengine
andthenanextra3/4turniscompleted.
3.Fillthecrankcasewiththepropertypeofnewoil; refertoChangingtheOil.
37
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ServicingtheSparkPlug
G013448
G013449
ServiceInterval:Every100hours
Makesuretheairgapbetweenthecenterandside electrodesiscorrectbeforeinstallingthesparkplug. Useasparkplugwrenchforremovingandinstalling thesparkplug(s)andagappingtool/feelergaugeto checkandadjusttheairgap.Installanewsparkplug(s) ifnecessary.
Note:Therearedifferentsparkplugsforthe23hp, 27hp,29hp,and34hpengines.Ensurethecorrectspark plugisused.
Typefor23hp,27hp,and29hpEngines:NGK BPR4ESorequivalent
Typefor34hpEngines:NGK
®
BPR5ESorequivalent
AirGap:0.030inch(0.75mm)
RemovingtheSparkPlug
1.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
3.Removethelefthandhydraulicunitshroudinthe orderlistedwith tothefrontsparkplug.
Figure50.Thisgivesyouaccess
®
Figure50
1.Pullthistabouttothe sideinthedirectionofthe arrow
2.Pulltheshroudoffofthis frametabinthedirection ofthearrow
3.Pulltheshroudoffofthis frametabinthedirection ofthearrow
4.Shroud
4.Removethesparkplug.
Figure51
5.Installthelefthandhydraulicunitshroud(Figure50).
38
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CheckingtheSparkPlug
G008794
1
2
CheckSparkArrester(if
Important:Nevercleanthesparkplug(s).Always
replacethesparkplug(s)whenithas:ablack coating,wornelectrodes,anoilylm,orcracks.
Ifyouseelightbrownorgrayontheinsulator,the engineisoperatingproperly.Ablackcoatingonthe insulatorusuallymeanstheaircleanerisdirty.
Setthegapto0.030inches(0.76mm).
Figure52
InstallingtheSparkPlug
Tightenthesparkplug(s)to16ft.-lb(22N-m).
equipped)
ServiceInterval:Every50hours
WARNING
Hotexhaustsystemcomponentsmayignite gasolinevaporsevenaftertheengineisstopped. Hotparticlesexhaustedduringengineoperation mayigniteammablematerials.Firemayresultin personalinjuryorpropertydamage.
DoNotrefuelorrunengineunlesssparkarrester isinstalled.
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Waitformufertocool.
3.Ifanybreaksinthescreenorweldsareobserved, replacethearrester.
4.Ifpluggingofthescreenisobserved,removethe arresterandshakelooseparticlesoutofthearrester andcleanscreenwithawirebrush(soakinsolventif necessary).Reinstallarresteronexhaustoutlet.
Figure53
39
Page 40
FuelSystem Maintenance
InspectingtheLPGSystem
ServiceInterval:Beforeeachuseordaily
Every40hours
ItisveryimportanttochecktheLPGtankand componentsforwearorleaks.
Important:Nevercheckforleaksusinganopen ame.
Important:Neverusebarehandswhenchecking thettingorvalve.EscapingLPGvaporandliquid freezesskinoncontact.
Inspectingbeforeeachuse:
Visuallyinspectthetank,hose,andttingandbe
alerttoafoulodorcomingfromthetank.
TheLPGtankshouldbefreeofdentsordamage.
Ifthetankshowsignsofdentsordamage, replaceitimmediately.
Checkthevalveandttingopeningsfordirtand
debris.
Slowlyopenthevalveallthewayandlistenfor
acontinuoushissfromtheregulator,itmay indicatealeak.
LPGhasarotteneggorskunksmelladdedtoit
tohelpdetectagasleak.Ifyoudetectagasleak:
TurnofftheLPGvalveifyoucansafelydo
so.
Leavethearea.
Contacttrainedandqualiedpersonnel
immediately.
DoNotuseifthehosesareabraded,damaged,
kinked,orattened.
Makesurethetankissecurelymountedtothe
mower.Ifthetankisloose,thehoseorttings mayleak.
Applyanapprovedleakdetectorsolution,
obtainedfromatrainedandqualiedLPG distributor,orathicknon-ammoniasoapy watersolution(50%non-ammoniasoapand 50%water).(Aleakdetectorsolutionthat containsammoniawillcausethettingsto corrodeandleak.)
Usingasmallbrushorspraybottle,applythe
solutionaroundallthettingsoftheLPG tankandthefuelconnectionjoint.
Slowlyopenthegasvalveahalf-turn.
Ifbubblesaredetected,thejointorttinghas
aleak.Shutoffthevalve,tightentheleaking connection,andslowlyopenthevalveagain. Ifbubblesstillappear,DoNotusethetank. Ifitissafetodoso,removethetankfrom yourmower;otherwise,contacttrainedand qualiedpersonnelimmediately .
Ifnobubblesaredetected,theLPGtank
maybeused.
Inspectingweekly:
ChecktheLPGhoses,regulatorandconnections
fordamageordeterioration.
ChecktheLPGhoses,regulatorandconnections
forleaksatalljointsusingthesamemethodas describedintheprevioussection.
Followalltheinspectionchecksasspeciedin
thetwopreviousinspectionsections.
TankRequalication:
USDOT(UnitedStatesDepartmentof
Transportation)regulationsrequireLPGtanksto beinspected,requalied,andmarkedwithin12 yearsofthemanufacturedateandonaregular basisthereafter.Typicallythisoccurswhenthe tankisrelled;contactatrainedandqualied LPGtankproviderformoredetails.
DoNotlltheLPGtankifitisbeyondthe
requalicationperiod.
DoNotlldamagedorrustedLPGtanks.
Inspectingwitheachtankchange:
Checkallgauges,ttings,andvalvesfordamage.
Lookfordeterioration,damagedormissing
o-ringsontankconnectiontting.
InspecttheLPGtankandthefuelconnection
jointforleaks.Usethefollowingprocedure belowtodetectleaks:
40
Page 41
ElectricalSystem Maintenance
ServicingtheBattery
ServiceInterval:Monthly
WARNING
CALIFORNIA
Proposition65Warning
WARNING
Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.
AlwaysDisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.
AlwaysReconnectthepositive(red)battery cablebeforereconnectingthenegative(black) cable.
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
W ash hands after handling .
DANGER
Batteryelectrolytecontainssulfuricacidwhichisa deadlypoisonandcausessevereburns.
Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing .Wearsafetyglassestoshield youreyesandrubberglovestoprotectyourhands.
RemovingtheBattery
WARNING
Batteryterminalsormetaltoolscouldshortagainst metalmachinecomponentscausingsparks.Sparks cancausethebatterygassestoexplode,resulting inpersonalinjury.
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Firstdisconnectthenegativebatterycable(black) fromthenegative(-)(black)batteryterminal
Figure54).
(
4.Slidetheredterminalbootoffthepositive(red) batteryterminalandremovethepositive(+)(red) batterycable(
5.Removethewingnutsecuringthebatteryclamp (Figure54).
6.Removetheclamp(Figure54).
7.Removethebattery.
Figure54).
Whenremovingorinstallingthebattery,donot allowthebatteryterminalstotouchanymetal partsofthemachine.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
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G013447
+
-
+
-
+
-
G008964
1
2
3
4
Important:Alwayskeepthebatteryfullycharged (1.265specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32°F(0°C).
1.Chargebatteryfor10to15minutesat25to30amps or30minutesat10amps.
2.Whenthebatteryisfullycharged,unplugthecharger fromtheelectricaloutlet,thendisconnectthe chargerleadsfromthebatteryposts(
Figure55).
3.Installthebatteryinthemachineandconnectthe batterycables,refertoInstallingtheBattery.
Note:Donotrunthemachinewiththebattery disconnected,electricaldamagemayoccur.
Figure54
1.Removethewingnutand clamp
2.Removethenegative batterycablebeforethe positive
3.Removethepositive batterycable
4.Removebattery
InstallingtheBattery
1.Positionbatteryinthetraywiththeterminalposts oppositefromthehydraulictank(Figure54).
2.First,installthepositive(red)batterycableto positive(+)batteryterminal.
3.Theninstallthenegative(black)batterycableand groundwiretothenegative(-)batteryterminal.
4.Securethecableswith2bolts,2washers,and 2locknuts(Figure54).
5.Slidetheredterminalbootontothepositive(red) batterypost.
6.Installtheclampandsecureitwiththewingnut (Figure54).
1.PositiveBatteryPost
2.NegativeBatteryPost
Figure55
3.Red(+)ChargerLead
4.Black(-)ChargerLead
ChargingtheBattery
WARNING
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparksand amesawayfrombattery.
42
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ServicingtheFuses
DriveSystem
Theelectricalsystemisprotectedbyfuses.Itrequires nomaintenance,however,ifafuseblowscheckthe component/circuitforamalfunctionorshort.
1.Thefusesarelocatedonrighthandconsolenextto theseat(Figure56).
2.Toreplacethefuses,pulloutonthefusetoremove it.
3.Installanewfuse(
Figure56).
Maintenance
CheckingtheSeatBelt
ServiceInterval:Beforeeachuseordaily
Visuallyinspectseatbeltforwear,cuts,andproper operationofretractorandbuckle.Replacebefore operatingifdamaged.
CheckingtheRollover ProtectionSystem(ROPS) Knobs
ServiceInterval:Beforeeachuseordaily
Checkthatboththemountinghardwareandtheknobs areingoodworkingcondition.Makesuretheknobs arefullyengagedwiththeROPSintheraisedposition. Theupperhoopoftherollbarmayneedtobepushed forwardorpulledrearwardtogetbothknobsfully engaged.
Figure56
1.Optionalaccesory-15amp
2.Charge-25amp5.Console
3.PTO-10amp
4.Main-25amp
43
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g013441
2 1
3
4
Figure57
G013450
1.ROPSknob(locked position)
2.PullROPSknoboutand rotate90degreesto changerollbarposition
AdjustingtheTracking
3.Rollbarintheupright position
4.Rollbarinthefolded position
1.Disengagethebladecontrolswitch(PTO).
2.Drivetoanopenatarea,movethemotioncontrol leverstotheneutrallockedposition.
3.Movethethrottlemidwaybetweenfastandslow.
4.Movebothmotioncontrolleversallthewayforward untiltheybothhitthestopsintheT-slot.
5.Checkwhichwaythemachinetracks.
Figure58
Leftcontrollevershown
1.Controllever3.Stopplate
2.Bolt
CheckingtheTirePressure
ServiceInterval:Every50hours/Monthly(whichever
comesrst)
Maintaintheairpressureinthereartiresat13psi(90 kPa).Uneventirepressurecancauseunevencut.Check thetireswhentheyarecoldtogetthemostaccurate pressurereading.
Note:Thefronttiresaresemi-pneumatictiresanddo notrequireairpressuremaintenance.
6.Ifittrackstotheright,loosentheboltsandadjust theleftstopplaterearwardontheleftT-slotuntil themachinetracksstraight(Figure58).
7.Ifittrackstotheleft,loosentheboltsandadjustthe rightstopplaterearwardontherightT-slotuntilthe machinetracksstraight(Figure58).
8.Tightenthestopplate(Figure58).
Figure59
44
Page 45
CheckingtheWheelHub SlottedNut
ServiceInterval:Aftertherst100hours
Every500hours
nuttoaligntheslot.Ifrequired,tightentothe nextsetofslots.
7.Installanewcotterpin.
Note:DoNotuseanti-seizeonwheelhub.
SeeFigure60todeterminewhichslottednuthasbeen installedontheunit.
Figure60
1.StyleA(blacknish)3.StyleB(yellowzinc)
2..03inch(.76mm)4..24inch(6mm)
StyleA(blacknish):
Torquetheslottednutto211-260ft-lb(286-352 N-m).
Note:DoNotuseanti-seizeonwheelhub.
StyleB(yellowzinc):
1.Removeanddiscardthecotterpin.
2.Torquetheslottednutto200ft-lb(271N-m).
AdjustingtheCasterPivot Bearing
ServiceInterval:Every500hours/Y early(whichever
comesrst)
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removethedustcapfromcasterandtightenlock nut(Figure62).
4.Tightenthelocknutuntilthespringwashersareat andthenbackoffa1/4turntoproperlysetthe pre-loadonthebearings(Figure62).
Important:Makesurethespringwashersare installedcorrectlyasshowninFigure62.
5.Installthedustcap(Figure62).
3.Checkdistancefrombottomofslotinnutto insideedgeofhole.Twothreads(0.1inch)or lessshouldbeshowing.
Figure61
1.0.1inchmax2.Nomorethantwothreads (0.1inchmax)shouldbe showinghere.
4.Ifmorethantwothreads(0.1inch)areshowing removenutandinstallwasherbetweenhuband nut.
5.Torquetheslottednutto200ft-lb(271N-m).
6.Thentightennutuntilthenextsetofslotsline upwiththecrossholeinshaft.Donotloosen
Figure62
1.SpringWashers3.DustCap
2.LockNut
UsingtheClutchShim
Somelatermodelyearunitshavebeenbuiltwith clutchesthatcontainabrakeshim.Whentheclutch brakehasworntothepointwheretheclutchnolonger
45
Page 46
engagesconsistently,theshimcanberemovedtoextend theclutchlife.
Figure63
1.Armature5.Brakespacer
2.Fieldshell6.Re-gapshim
3.Rotor7.Brakepole
4.Brakemountingbolt
RemovingtheClutchShim
1.Stoptheengine,waitforallmovingpartstostop, andremovethekey.Engagetheparkingbrake. Allowthemachinetocoolcompletelybeforestarting theseinstructions.
Note:DoNotremovethebrakepolefromthe eldshell/armature.Thebrakepolehasworn tomatchthearmatureandneedstocontinueto matchaftertheshimisremovedtoensureproper braketorque.
Figure65
1.Brakemountingbolt
B.Usingneedlenosepliers,orbyhand,takehold
ofthetabandremovetheshim(DoNotdiscard theshimuntilproperclutchfunctionhasbeen conrmed).
2.Usinganaircompressor,blowoutanydebrisfrom underthebrakepoleandaroundthebrakespacers.
Figure64
3.Checktheconditionofthewireharnessleads, connectors,andterminals.Cleanorrepairas necessary.
4.Verifythat12Vispresentattheclutchconnector whenthePTOswitchisengaged.
5.Measurethegapbetweentherotorandarmature. Ifthegapisgreaterthan.04inch(1mm),proceed withthefollowingsteps:
Figure66
1.Shim
C.Usingapneumaticline,blowoutanydebris
fromunderthebrakepoleandaroundthebrake spacers.
D.Re-torqueeachbolt(M6x1)to10ft-lb(13N-m)
+/-0.5ft-lb(0.7N-m).
E.Usinga0.010inchthickfeelergauge,verifythat
agapispresentbetweentherotorandarmature faceonbothsidesofthebrakepoleasshown. (Duetothewaytherotorandarmaturefaces wear(peaksandvalleys)itissometimesdifcult tomeasurethetruegap.)
A.Loosenbothbrakemountingboltsone-halfto
onefullturnasshownbelow .
46
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1.Feelergauge
G013447
1.Feelergauge
CoolingSystem Maintenance
CleaningtheEngineScreen andEngineOilCooler
Figure67
ServiceInterval:Beforeeachuseordaily
Removeanybuild-upofgrass,dirtorotherdebrisfrom theoilcooler(Figure69).
Figure68
Ifthegapislessthan0.010inch,thenreinstall theshimandreferencetheTroubleshooting section.
Ifthegapissufcient,proceedtothesafety checkinstep
F.Performthefollowingsafetycheck:
a.Sitontheseatandstarttheengine.
b.MakesurethebladesDoNotengagewiththe
PTOswitch“off”andtheclutchdisengaged.
Iftheclutchdoesnotdisengage,reinstallthe shimandreferencetheTroubleshooting section.
c.EngageanddisengagethePTOswitch
tenconsecutivetimestoensuretheclutch isfunctioningproperly.Iftheclutch doesnotengageproperly,referencethe Troubleshootingsection.
F.
Figure69
Beforeeachuseremoveanybuild-upofgrass,dirtor otherdebrisfromtheenginescreen.Thiswillhelp insureadequatecoolingandcorrectenginespeedand willreducethepossibilityofoverheatingandmechanical damagetotheengine(Figure70).
CleaningtheEngineCooling FinsandShrouds
ServiceInterval:Every100hours/Y early(whichever
comesrst)
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removetheairintakescreen,recoilstarterandfan housing(
Figure70).
4.Cleanthedebrisandgrassfromtheengineparts.
5.Installairintakescreen,recoilstarterandfanhousing (Figure70).
47
Page 48
Figure70
G013448
1.Engineguard4.Fanhousing
2.Engineairintakescreen
3.Bolt
5.Screw
CheckandCleantheHydraulic UnitShrouds
ServiceInterval:Beforeeachuseordaily
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisetheseat.
4.Cleanthedebrisandgrassfromthehydraulicunit shrouds(
5.Lowertheseat.
Figure71).
Figure71
1.Hydraulicunitshrouds
48
Page 49
BrakeMaintenance
standardnut.DoNotallowthecabletoturnwhen thenutsaretightened.
AdjustingtheParkingBrake
ServiceInterval:Aftertherst100hours
Every500hours
DANGER
Mechanicalorhydraulicjacksmayfailtosupport machineandcauseaseriousinjury.
Usejackstandwhensupportingmachine.
Donotusehydraulicjacks.
Checktomakesurethebrakeisadjustedproperly.
1.Drivethemachineontoalevelsurface.
2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
3.Stoptheengine,waitforallthemovingpartstostop, andremovethekey.
4.Raisethebackofthemachineupandsupportthe machinewithjackstands.
15.Closethedrivewheelreleasevalve.RefertoUsing theDriveWheelValvesinOperation.
16.Repeatontheoppositesideofthemachine.
17.Installthereartiresandtorquethelugnutsto90-95 ft-lb(122-129N-m).
18.Removejackstands.
5.Removethereartiresfromthemachine.
6.Removeanydebrisfromthebrakearea.
7.Openthedrivewheelreleasevalves.RefertoUsing theDriveWheelValvesinOperation.
8.Disengagetheparkingbrake.
9.Usinghandsandngersonly,pushthecaliperlever armtoengagethebrakepadsontherotoruntilthe leverstops(
Figure72).
Notetheorderofthestandardnutandlocknut.
10.Whileholdingtheleveratthestoppedposition,use theotherhandorngerstopullthecablethreaded endtightthroughtheswivel.Spinthestandardnut againsttheswivel(
Figure72).
11.Trytoturnthewheelhubinbothdirectionsrelative tothecaliper.Thereshouldbeslightmovement betweenthem;somefriction/resistanceisacceptable.
12.Ifthereisnomovementbetweenthehubrotorand thecaliperthenbackoffthestandardnutoneturn fromtheswivelandrepeatstep11
Figure72
LeftHandBrakeShown
1.Cableanchor
2.Threadedrod7.Pullcablethreadedrod
3.Pushleverthisdirection8.Holdthreadedrodhere
4.Caliperleverarm9.Swivel(pivothead)
5.Standardnut(shown againstswivel)
6.Locknut
thisdirection
13.Ifthehubrotormovesveryfreelyrelativetothe caliper,thentightenthestandardnutoneturn againsttheswivelandrepeatstep11
14.Oncestep11isachieved,holdthethreadedrod endwithatoolandtightenthelocknutagainstthe
49
Page 50
BeltMaintenance
G009036
1
2
InspectingtheBelts
ServiceInterval:Every50hours
Checkthebeltsforsquealingwhenthebeltisrotating, bladesslippingwhencuttinggrass,frayedbeltedges, burnmarksandcracksaresignsofawornmowerbelt. Replacethemowerbeltifanyoftheseconditionsare evident.
ReplacingtheMowerBelt
Squealingwhenthebeltisrotating,bladesslippingwhen cuttinggrass,frayedbeltedges,burnmarksandcracks aresignsofawornmowerbelt.Replacethemowerbelt ifanyoftheseconditionsareevident.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Lowerthemowertothe3inch(76mm)heightofcut.
4.Removethebeltcovers(
1.Pushtabdown2.Removebeltcover
5.Usearatchetinthesquareholeintheidlerarmto removetensionontheidlerspring(
6.Removethebeltfromthemowerdeckpulleys.
7.Removethebeltguideonthespringloadedidler armshownin
Figure74.
Figure73).
Figure73
Figure74).
Figure74
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt6.Idlergreasezerk
3.Springloadedidlerpulley
4.Ratchet
10.Installthebeltguideontheidlerarmshownin Figure74.
11.Usingtheratchetinthesquarehole,installtheidler spring(Figure74).
Makesurethespringendsareseatedintheanchor grooves.
12.Installthebeltcovers(
armfortheratchet
7.Beltguide
Figure75).
8.Removetheexistingbelt.
9.Installthenewbeltaroundthemowerpulleysand theclutchpulleyundertheengine(Figure74).
50
Page 51
Figure75
1.Positionthebeltcover3.Ensurethetabisunder
2.Slidebeltcoverunderthe sidecatches
themetalcatch
ReplacingtheHydraulicPump DriveBelt
1.DisengagethePTOandsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Removemowerbelt.RefertoReplacingtheMower BeltinMaintenance.
4.Raisethemachineandsupportitwithjackstands
Figure76).
(
Figure76
1.Idlerpulley
2.Clutchpulley6.Squareholeinidlerarm
3.Pumpdrivebelt7.Idlerspring
4.Righthandhydraulicpump pulley
5.Lefthandhydraulicpump pulley
5.Usearatchetinthesquareholeintheidlerarmto removetheidlerspring(Figure76).
6.Unhooktheidlerspringfromtheframe(Figure76).
7.Removethebeltfromthehydraulicunitdrivepulleys andtheenginepulley
8.Installthenewbeltaroundenginepulleyandthe twodrivepulleys.
9.Usingaratchetinthesquareholeintheidlerarm, installtheidlerspringtotheframe(
Figure76).
10.Installthemowerbelt.RefertoReplacingthe MowerBelt.
51
Page 52
ControlsSystem Maintenance
AdjustingtheControlHandle Position
Therearetwoheightpositionsforthecontrollevers; highandlow.Removetheboltstoadjusttheheightfor theoperator.
1.DisengagethePTO,movethemotioncontrollevers totheneutrallockedposition,andsettheparking brake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Loosentheboltsandangenutsinstalledinthe levers(
Figure77).
Figure78
4.Aligntheleversfronttorearpositionbybringthe leverstogethertotheneutralpositionandslide themuntiltheyarealigned,thentightenthebolts (Figure78).
Figure77
1.Bolt
2.Handle4.Nut
3.Controllever
AdjustingtheMotionControl Linkage
Locatedoneithersideofthefueltank,belowtheseatare thepumpcontrollinkages.Rotatingthepumplinkage witha1/2inchwrenchallowsnetuningadjustments sothatthemachinedoesnotmoveinneutral.Any adjustmentsshouldbemadeforneutralpositioningonly.
WARNING
Enginemustberunninganddrivewheelsmust beturningsomotioncontroladjustmentcanbe performed.Contactwithmovingpartsorhot surfacesmaycausepersonalinjury.
Keepngers,hands,andclothingclearofrotating componentsandhotsurfaces.
1.Priortostartingtheengine,pushthedeckliftpedal andremovetheheightofcutpin.Lowerdeckto theground.
2.Raisetherearofmachineupandsupportwithjack stands(orequivalentsupport)justhighenoughto allowdrivewheelstoturnfreely.
3.Removetheelectricalconnectionfromtheseat safetyswitch,locatedunderthebottomcushionof theseat.Theswitchisapartoftheseatassembly.
4.Temporarilyinstallajumperwireacrossthe terminalsintheconnectorofthemainwiring harness.
5.Startengine.Brakemustbeengagedandmotion
controlleversouttostartengine.Operatordoes
52
Page 53
nothavetobeintheseatbecauseofthejumper
G013451
wirebeingused.Runengineatfullthrottleand releasebrake.
AdjustingtheMotionControl Damper
6.Runtheunitatleast5minuteswiththedrivelevers atfullforwardspeedtobringhydraulicoilupto operatingtemperature.
Note:Themotioncontrolleverneedstobein neutralwhilemakinganynecessaryadjustments.
7.Bringthemotioncontrolleversintotheneutral position.Adjustpumpcontrolrodlengthsby rotatingthedoublenutsontherodintheappropriate directionuntilthewheelsslightlycreepinreverse
Figure79).Movethemotioncontrolleverstothe
( reversepositionandwhileapplyingslightpressureto theleverallowthereverseindicatorspringstobring theleversbacktoneutral.Thewheelsmuststop turningorslightlycreepinreverse.
Thetopdampermountingboltcanbeadjustedto obtainamoredesiredmotioncontrolleverresistance.
Figure80formountingoptions.
See
Figure80
RHMotionControlShown
1.Torquethelocknutto200in-lb(16.7ft-lb).Boltmust protrudepastendoflocknutaftertorque.
2.Mostresistance(rmestfeel)
3.Damper
4.Mediumresistance(mediumfeel)
5.Leastresistance(softestfeel)
Figure79
1.Doublenuts
8.Shutoffunit.Removejumperwirefromwire harnessandplugconnectorintoseatswitch.
9.Removethejackstands.
10.Raisethedeckandre-installtheheightofcutpin.
11.Checkthatthemachinedoesnotcreepinneutral withtheparkbrakesdisengaged.
AdjustingtheMotionControl NeutralLockPivot
Theangednutcanbeadjustedtoobtainamoredesired motioncontrolleverresistancewhenmovingittothe neutrallockposition.See options.
1.Loosenthejamnut.
2.Tightenorloosentheangednuttothedesiredfeel.
Formoreresistance,tightentheangednut.
Forlessresistance,loosentheangednut
3.Tightenjamnut.
Figure81foradjustment
53
Page 54
HydraulicSystem Maintenance
ServicingtheHydraulic System
Figure81
1.Flangednut2.Jamnut
115W-50.
®
HYPR-OIL
HydraulicOilType:Toro hydraulicoilorMobil
Important:Useoilspecied.Otheruidscould causesystemdamage.
EachHydraulicSystemOilCapacity:52ounces(1.5
l)persidewithlterchange
®
500
CheckingtheHydraulicOil
ServiceInterval:Every50hours—Checkthehydraulic
oillevel.
1.Positionthemachineonalevelsurface.
2.DisengagethePTO,movethemotioncontrollevers totheneutrallockedpositionandsettheparking brake.
3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
4.Allowtheenginetoandhydraulicsystemtocoolfor tenminutes.
5.Raisetheseatup.
6.Cleantheareaaroundthedipsticksofhydraulic systemreservoirs(
7.Removeonedipstickfromthehydraulicreservoir
Figure82).
(
8.Wipethedipstickoffandthreadthedipstickinto thereservoir.
9.Removethedipstickandlookatthemetalend
Figure82).Thelevelneedstobewithinknurled
( section.Ifoillevelislow ,slowlypouronlyenough oilintothehydraulicreservoirtoraisethelevelto theknurledsection.
Important:Donotoverllthehydraulicunits withoilasdamagemayoccur.Donotrunthe machinewithoilbelowtheknurledsection becausedamagemayoccur.
10.Installthedipstick.
Figure82).
54
Page 55
ReplacingtheHydraulicFiltersand HydraulicOil
ServiceInterval:Every250hours
Every500hours
Toreplacethehydraulicoil,theltersneedtobe removed.Replacebothatthesametime.Refertothe oilspecicationsunderServicingtheHydraulicSystem forthecorrectoil.
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethemachineandsupportitwithjackstands
Figure83).
(
Figure82
Topview(underseat)
1.Oilneedstobewithin knurledsection
2.Dipsticklocations
WARNING
Hydraulicoilescapingunderpressurecan penetrateskinandcauseinjury .
Ifhydraulicoilisinjectedintotheskinit mustbesurgicallyremovedwithinafew hoursbyadoctorfamiliarwiththistypeof injury.Gangrenemayresultifthisisnot done.
Keepbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicoil.
Usecardboardorpapertondhydraulic leaks.
Safelyrelieveallpressureinthehydraulic systembeforeperforminganyworkonthe hydraulicsystem.
Figure83
1.Jackstands
4.Removeboththemowerbeltandthepumpdrive belt.Thiswillpreventoilgettingonthebelts.Refer toBeltsintheMaintenanceSection.
5.Placeadrainpanunderthelter,removetheold lterandwipethesurfaceclean(Figure84).
Makesureallhydraulicoilhosesandlines areingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretohydraulicsystem.
55
Page 56
G008968
1
2
MowerDeck Maintenance
LevelingtheMowerDeck
SettingUptheMachine
Note:Ensurethemowerdeckisleveledbefore
matchingtheheight-of-cut(HOC).
1.Positionmoweronaatsurface.
2.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
3.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
Figure84
BottomViewofMachine
1.Filterlocations
2.Hydrauliclter
4.Checktirepressureofthedrivetires.Ifneeded, adjustto13psi(90kPa)
5.Positionthemowertothe3inch(76mm) height-of-cutposition.
6.Applyathincoatofhydraulicoiltotherubber gasketonthereplacementlter(
7.Installthereplacementhydrauliclter.
8.Installthepumpdrivebeltandthemowerbelt.
9.Removethejackstandsandlowerthemachine
Figure83).
(
10.Addoiltothehydraulicreservoirandcheckforany leaks.
11.Cleanupanyspilledoil.
12.Starttheengineandletitrunforabouttwominutes topurgeairfromthesystem.Stoptheengineand checkforleaks.
13.Checktheoillevelwhiletheoiliscold.
14.Ifrequired,addoiltothehydraulicreservoir.Do notoverll.
Figure84).
DeckLeveling
1.Positionthemoweronaatsurface.
2.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
3.Checkthetirepressureinthedrivetires.Proper inationpressurefortiresis13psi(90kPa).Adjust ifnecessary.
4.Positionthetransportlockinthelatchingposition.
5.Pushthedeckliftpedalallthewayforwardandthe deckwilllatchatthe51/2inch(14cm)transport position(
Figure85).
Figure85
1.Deckliftpedal
2.Heightofcutpin
56
3.Transportlock
Page 57
6.Inserttheheightadjustmentpinintothe3inch(7.6
1
2
2 1
3 4
g013452
cm)cuttingheightlocation.
7.Releasethetransportlockandallowthedeckto lowertothecuttingheight.
8.Raisethedischargechute.
9.Onbothsidesofthedeck,measurefromthelevel surfacetothefronttipoftheblade(PostionA). Themeasurementshouldread3inches(7.6mm)
Figure86).
(
Figure87
1.Adjustmentnut3.Reardeckadjustment
2.JamNut4.Frontdeckadjustment
11.Ifthefrontdecklinksdonothaveenough adjustmenttoachieveaccuratecutheight,the singlepointadjustmentcanbeutilizedtogainmore adjustment.
1.3inches(7.6cm)atAis correct
2.31/4inches(8.3cm)atB iscorrect
Figure86
3.Measureherefromthe bladetiptohardsurface
4.MeasureatAandBon bothsides
12.Toadjustthesinglepointsystem,loosenthetwo boltsatthebottomoftheheightofcutplate.Refer
10.Fine-tunetheadjustmentnutonthefrontdecklift
toFigure88.
assemblybyturningit(Figure87).
Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.
Figure88
1.Boltsatthebottomoftheheight-of-cutplate
57
Page 58
13.Ifthedeckistoolow ,tightenthesinglepoint adjustmentboltbyrotatingitclockwise.Ifthedeck istoohigh,loosenthesinglepointadjustmentbolt byrotatingitcounterclockwise(
Figure89).
Note:Loosenortightenthesinglepointadjustment boltenoughtomovetheheight-of-cutplate mountingboltsatleast1/3thelengthoftheavailable travelintheirslots.Thiswillregainsomeupand downadjustmentoneachofthefourdecklinks.
Figure89
1.Singlepointadjustmentbolt
ServicingtheCuttingBlades
Maintainsharpbladesthroughoutthecuttingseason becausesharpbladescutcleanlywithouttearingor shreddingthegrassblades.Tearingandshreddingturns grassbrownattheedges,whichslowsgrowthand increasesthechanceofdisease.
Checkthecutterbladesdailyforsharpness,andforany wearordamage.Filedownanynicksandsharpenthe bladesasnecessary.Ifabladeisdamagedorworn, replaceitimmediatelywithagenuineTororeplacement blade.Forconvenientsharpeningandreplacement,you maywanttokeepextrabladesonhand.
DANGER
Awornordamagedbladecanbreak,andapiece ofthebladecouldbethrownintotheoperator’s orbystander’sarea,resultinginseriouspersonal injuryordeath.
Inspectthebladeperiodicallyforwearor damage.
Replaceawornordamagedblade.
BeforeInspectingorServicingthe Blades
14.Tightenthetwoboltsatthebottomoftheheightof cutplate(Figure88).Torqueto27-33ft-lb(37-45 N-m).
Note:Inmostconditions,thebackbladetipshould beadjusted1/4inch(6.4mm)higherthanthefront.
15.Onbothsidesofthedeck,measurefromthelevel surfacetothebacktipoftheblade(PostionB).The measurementshouldread31/4inches(8.3cm)
Figure86).
(
16.Fine-tunetheadjustmentnutonthefrontdecklift assemblybyturningit(Figure87).
Toincreasetheheight,turntheadjustmentnut clockwise;todecrease,turncounterclockwise.
17.Measureuntilallfoursidesarethecorrectheight. Tightenallthejamnutsonthedeckliftarm assemblies.
18.Lowerdischargechute.
Parkthemachineonalevelsurface,disengagetheblade controlswitch(PTO),andsettheparkingbrake.Turn theignitionkeytoOff.Removethekey.
InspectingtheBlades
ServiceInterval:Beforeeachuseordaily
1.Inspectthecuttingedges( arenotsharporhavenicks,removeandsharpenthe blades.RefertoSharpeningtheBlades.
2.Inspecttheblades,especiallythecurvedarea
Figure90).Ifyounoticeanydamage,wear,oraslot
( forminginthisarea(Figure90),immediatelyinstalla newblade.
Figure90).Iftheedges
Figure90
1.CuttingEdge3.Wear/slotForming
2.CurvedArea4.Crack
58
Page 59
CheckingforBentBlades
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Rotatethebladesuntiltheendsfaceforwardand backward(Figure91).Measurefromalevelsurface tothecuttingedge,positionA,oftheblades
Figure91).Notethisdimension.
(
performanceandcontinuedsafetyconformanceof themachine,usegenuineTororeplacementblades. Replacementbladesmadebyothermanufacturersmay resultinnon-conformancewithsafetystandards.
1.Holdthebladeendusingaragorthickly-padded glove.
2.Removethebladebolt,curvedwasher,andblade fromthespindleshaft(
Figure92).
Figure91
1.Measureherefromblade tohardsurface
2.PositionA
4.Rotatetheoppositeendsofthebladesforward.
5.Measurefromalevelsurfacetothecuttingedgeof thebladesatthesamepositionasinstep
3above. Thedifferencebetweenthedimensionsobtainedin steps3and4mustnotexceed1/8inch(3mm).If thisdimensionexceeds1/8inch(3mm),theblade isbentandmustbereplaced;refertoRemovingthe BladesandInstallingtheBlades.
WARNING
Abladethatisbentordamagedcouldbreak apartandcouldseriouslyinjureorkillyouor bystanders.
Alwaysreplacebentordamagedbladewith anewblade.
Neverleorcreatesharpnotchesinthe edgesorsurfacesofblade.
Figure92
1.SailAreaofBlade3.Curvedwasher
2.Blade4.BladeBolt
SharpeningtheBlades
WARNING
Whensharpeningblade,piecesofbladecouldbe thrownandcauseseriousinjury .
Wearpropereyeprotectionwhensharpeningblade.
1.Usealetosharpenthecuttingedgeatbothends oftheblade(Figure93).Maintaintheoriginalangle. Thebladeretainsitsbalanceifthesameamountof materialisremovedfrombothcuttingedges.
RemovingtheBlades
Bladesmustbereplacedifasolidobjectishit,ifthe bladeisoutofbalanceorisbent.Toensureoptimum
59
Page 60
Figure93
1.Sharpenatoriginalangle
2.Checkthebalanceofthebladebyputtingitona bladebalancer(Figure94).Ifthebladestaysina horizontalposition,thebladeisbalancedandcanbe used.Ifthebladeisnotbalanced,lesomemetaloff theendofthesailareaonly(Figure95).Repeatthis procedureuntilthebladeisbalanced.
Figure94
1.Blade2.Balancer
InstallingtheBlades
1.Installthebladeontothespindleshaft(Figure95).
Important:Thecurvedpartoftheblademust bepointingupwardtowardtheinsideofthe mowertoensurepropercutting.
2.Installthespringdiskandbladebolt.Thespring diskconemustbeinstalledtowardthebolthead
Figure95).Torquethebladeboltto85-110ft-lb
( (115-150N-m).
1.SailAreaofBlade
2.Blade
3.SpringDisk
Figure95
4.BladeBolt
5.ConeT owardsBoltHead
60
Page 61
RemovingtheMowerDeck
Beforeservicingorremovingthemowerdeck,the springloadeddeckarmsmustbelockedout.
WARNING
Deckliftarmassemblieshavestoredenergy. Removingthedeckwithoutreleasingthestored energycancauseseriousinjuryordeath.
DoNotattempttodisassemblethedeckfromthe frontframewithoutlockingoutthestoredenergy.
1.Stopengine,waitforallmovingpartstostop,and removekey.Engageparkingbrake.
2.Removetheheightadjustmentpinandlowerthe decktotheground.
3.Placetheheightadjustmentpininthe3inch(7.6cm) cuttingheightlocation.Thislocksthedeckliftarms inthelowestpositionwhenthedeckisremovedand thestoredenergyinthedeckspringisreleased.
4.Removethebeltcovers.
5.Liftuptheoorpanandinsertaratchetintothe squareholeinthedeckidler(
Figure96).
6.Rotatethedeckidlerclockwiseandremovethe mowerbelt(Figure96).
Figure96
1.Clutchpulley5.Squareholeintheidler
2.Mowerbelt6.Idlergreasezerk
3.Springloadedidlerpulley
4.Ratchet
armfortheratchet
7.Beltguide
7.Removeandretainthehardwareonbothsidesofthe deckasshowninFigure97.
61
Page 62
Figure97
1.Rightstabilizer
2.Deckstrut(rightsideshown)
3.Removethereardeckliftattachmentshoulderboltandnut.
4.Removethefrontdeckliftattachmentshoulderboltandnut.
8.Raisethedeckstrutsandsecurethemintheup position.Slidethedeckouttotherightsideofthe machine.
Note:MakesuretheLendofthespringisinstalled behindthedeckedgebeforeinstallingtheboltas showninFigure98.
3.Installtheboltandnut.PlacetheJhookendofthe springaroundthegrassdeector(
Figure98).
Important:Thegrassdeectormustbeableto lowerdownintoposition.Liftthedeectorup totestthatitlowersintothefulldownposition.
Figure98
1.Bolt
2.Spacer6.GrassDeector
3.Locknut
4.Spring8.Jhookendofspring
5.Springinstalled
7.Lendofspring,place
behinddeckedgebefore installingbolt
ReplacingtheGrassDeector
WARNING
Anuncovereddischargeopeningcouldallowthe lawnmowertothrowobjectsintheoperator’sor bystander’sdirectionandresultinseriousinjury . Also,contactwiththebladecouldoccur.
Neveroperatethelawnmowerunlessyouinstall acoverplate,amulchplate,oragrasschuteand catcher.
Makesurethegrassdeectorisinthedown position.
1.Removethelocknut,bolt,springandspacerholding thedeectortothepivotbrackets(Figure98). Removethedamagedorworngrassdeector.
2.Placethespacerandspringontograssdeector. PlacetheLendofspringbehinddeckedge.
62
Page 63
Cleaning
Storage
CleaningUndertheMower
ServiceInterval:Beforeeachuseordaily
1.Disengagethebladecontrolswitch(PTO),movethe motioncontrolleverstotheneutrallockedposition andsettheparkingbrake.
2.Stoptheengine,removethekey,andwaitforall movingpartstostopbeforeleavingtheoperating position.
3.Raisethemowertothetransportposition.
WasteDisposal
Engineoil,batteries,hydraulicoil,andenginecoolant arepollutantstotheenvironment.Disposeofthese accordingtoyourstateandlocalregulations.
CleaningandStorage
Storageareasshouldbeequippedwithatleastone approvedportablereextinguisherhavingaminimum capacityof18lb(8.2kg)drychemicalwithaB:Crating. DoNotuseCarbonTetrachlorideextinguishers(Pyrene etc.).
1.Disengagethepowertakeoff(bladecontrolswitch (PTO),settheparkingbrake,andturntheignition keytoOff.Removethekey.
2.Removegrassclippings,dirt,andgrimefromthe externalpartsoftheentiremachine,especiallythe engineandhydraulicsystem.Cleandirtandchaff fromtheoutsideoftheenginecylinderheadnsand blowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotpressure washthemachine.Avoidexcessiveuseof water,especiallynearthecontrolpanel,engine, hydraulicpumps,andmotors.
3.Checkthebrake;refertoServicingtheBrakeinthe MaintenanceSection.
4.Servicetheaircleaner;refertoServicingtheAir CleanerintheMaintenanceSection.
5.Greasethemachine;refertoGreasingand LubricationintheMaintenanceSection.
6.Changethecrankcaseoil;refertoServicingthe EngineOilintheMaintenanceSection.
7.Checkthetirepressure;refertoCheckingtheTire PressureintheMaintenanceSection.
8.Changethehydrauliclters;refertoServicingthe HydraulicSystemintheMaintenanceSection.
9.Chargethebattery;refertoServicingtheBatteryin theMaintenanceSection.
10.Scrapeanyheavybuildupofgrassanddirtfromthe undersideofthemower,thenwashthemowerwith agardenhose.
Note:Runthemachinewiththebladecontrol switch(PTO)engagedandtheengineathighidle for2to5minutesafterwashing.
11.Checktheconditionoftheblades;refertoServicing theCuttingBladesintheMaintenanceSection.
12.Preparethemachineforstoragewhennon-use occursover30days.Restarttheengineandrunit untilitstops.
13.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.
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14.Paintallscratchedorbaremetalsurfaces.Paintis availablefromyourAuthorizedServiceDealer.
15.Storethemachineinaclean,drygarageorstorage area.Removethekeyfromtheignitionswitchand keepitoutofreachofchildrenorotherunauthorized users.Coverthemachinetoprotectitandkeepit clean.
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Troubleshooting
Problem
Starterdoesnotcrank
Enginewillnotstart,startshard,orfails tokeeprunning
PossibleCauseCorrectiveAction
1.Bladecontrolswitch(PTO)isengaged.1.Movebladecontrolswitch(PTO)to
2.Parkingbrakeisnoton.
3.Driveleversarenotinneutrallock position.
4.Operatorisnotseated.4.Sitontheseat.
5.Batteryisdead.
6.Electricalconnectionsarecorrodedor loose.
7.Fuseisblown.
8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.
1.LPGtankisempty.1.FilltheLPGtank.
2.Tankshutoffvalveisclosed.2.Openthetankshutoffvalve.
3.Oillevelinthecrankcaseislow.
4.Thethrottleisnotinthecorrectposition.4.Besurethethrottlecontrolismidway
5.Aircleanerisdirty.
6.Seatswitchisnotfunctioningproperly.6.Checktheseatswitchindicator.
7.Electricalconnectionsarecorroded, looseorfaulty.
8.Relayorswitchisdefective.8.ContactanAuthorizedServiceDealer.
9.Faultysparkplug.
10.Sparkplugwireisnotconnected.10.Checkthesparkplugwireconnection.
disengaged.
2.Settheparkingbrake.
3.Ensurethedriveleversareinthe neutrallockposition.
5.Chargethebattery.
6.Checktheelectricalconnectionsfor goodcontact.
7.Replacefuse.
3.Addoiltothecrankcase.
betweenthe“SLOW”and“FAST” positions.
5.Cleanorreplacetheaircleaner element.
Replaceseatifneeded.
7.Checktheelectricalconnections forgoodcontact.Cleanconnector terminalsthoroughlywithelectrical contactcleaner,applydielectricgrease andreconnect.
9.Clean,adjustorreplacesparkplug.
Enginelosespower.
Engineoverheats.
Mowerpullsleftorright(withleversfully forward)
Machinedoesnotdrive.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Aircleanerisdirty.
3.Oillevelinthecrankcaseislow.
4.Coolingnsandairpassagesabove theengineareplugged.
1.Engineloadisexcessive.1.Reducethegroundspeed.
2.Oillevelinthecrankcaseislow.
3.Coolingnsandairpassagesabove theengineareplugged.
1.Trackingneedsadjustment1.Adjustthetracking.
2.Tirepressureindrivetiresnotcorrect.2.Adjusttirepressureinthedrivetires.
1.Bypassvalvesisnotclosedtight.1.Tightenthebypassvalves.
2.Pumpbeltisworn,looseorbroken.
3.Pumpbeltisoffapulley .3.Changethebelt.
4.Brokenormissingidlerspring.4.Replacethespring.
5.Hydraulicoillevelislowortoohot.5.Addhydraulicoiltoreservoirsorletit
2.Cleantheaircleanerelement.
3.Addoiltothecrankcase.
4.Removetheobstructionfromthe coolingnsandairpassages.
2.Addoiltothecrankcase.
3.Removetheobstructionfromthe coolingnsandairpassages.
2.Changethebelt.
cooldown.
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Problem
PossibleCauseCorrectiveAction
Abnormalvibration.
Unevencuttingheight.
Bladesdonotrotate.
1.Cuttingblade(s)is/arebentor unbalanced.
2.Blademountingboltisloose.2.Tightentheblademountingbolt.
3.Enginemountingboltsareloose.3.Tightentheenginemountingbolts.
4.Looseenginepulley,idlerpulley,or bladepulley.
5.Enginepulleyisdamaged.
6.Bladespindleisbent.
7.Motormountislooseorworn.
1.Blade(s)notsharp.1.Sharpentheblade(s).
2.Cuttingblade(s)is/arebent.2.Installnewcuttingblade(s).
3.Mowerdeckisnotlevel.
4.Undersideofmowerisdirty .4.Cleantheundersideofthemower.
5.Tirepressureisnotcorrect.5.Adjustthetirepressure.
6.Bladespindlebent.
1.Mowerdeckbeltisworn,looseor broken.
2.Mowerdeckbeltisoffpulley.
3.Pumpdrivebeltisworn,looseor broken.
4.Brokenormissingidlerspring.4.Replacethespring.
1.Installnewcuttingblade(s).
4.Tightentheappropriatepulley.
5.ContactanAuthorizedServiceDealer.
6.ContactanAuthorizedServiceDealer.
7.ContactanAuthorizedServiceDealer.
3.Levelmowerdeckfromside-to-side andfront-to-rear.
6.ContactanAuthorizedServiceDealer.
1.Installnewdeckbelt.
2.Installmowerdeckpulleyandcheck theidlerpulley,idlerarmandspringfor correctpositionandfunction.
3.Checkthebelttensionorinstallnew belt.
Clutchwillnotengage.
1.Fuseisblown.
2.Lowvoltagesupplyattheclutch.
3.Damagedcoil.3.Replaceclutch.
4.Inadequatecurrentsupply.4.Repairorreplaceclutchleadwireor
5.Rotor/armatureairgapistoolarge.
1.Replacefuse.Checkcoilresistance, batterycharge,chargingsystem,and wiringconnectionsandreplaceif necessary.
2.Checkcoilresistance,battery charge,chargingsystem,andwiring connectionsandreplaceifnecessary .
electricalsystem.Cleanconnector contacts.
5.Removeshimorreplaceclutch.
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Schematics
G013876
BK = BL ACK
BN = B ROWN
BU = BLUE
GN = GREEN
GY = GREY
LT GR = LIGHT GREEN
OR = ORANGE
PK = PINK
R = RED
T = TAN
V = VIOLET
W = WHITE
LPG Electrical
Diagram
BLACK
BLACK
BLACK
BLACK
GREEN
GREEN
+
ENGINE
GROUND
OIL PRESSURE
SWITCH
ENGINE
LPG FUEL SHUT
OFF SOLENOID
RED
WireDiagram(Rev.A)
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TheToroTotalCoverageWarranty
ALimitedWarranty(seewarrantyperiodsbelow)
Landscape Contractor Equipment(LCE)
ConditionsandProductsCovered
TheT oroCompanyanditsafliate,T oroWarrantyCompany ,pursuantto anagreementbetweenthem,jointlypromisetotheoriginalpurchaser torepairtheT oroProductslistedbelowifdefectiveinmaterialsor workmanship.
Thefollowingtimeperiodsapplyfromthedateofpurchasebytheoriginal owner:
ProductsWarrantyPeriod
AllMowers
Engine**
Battery1year
Attachments1year
Mid-SizeWalk-BehindMowers GrandStand
Frame ZMaster
Engine
Frame
ZMaster
Frame
*Whicheveroccursrst.
**SomeenginesusedonT oroLCEProductsarewarrantedbytheenginemanufacturer.Kawasaki
FXengineshavea3yearwarrantytermforresidentialuse.Residentialusemeansuseofthe
productonthesamelotasyourhome.
***LifetimeFrameWarranty-Ifthemainframe,consistingofthepartsweldedtogethertoformthe
tractorstructurethatothercomponentssuchastheenginearesecuredto,cracksorbreaksin
normaluse,itwillberepairedorreplaced,atT oro’soption,underwarrantyatnocostforparts
andlabor.Framefailureduetomisuseorabuseandfailureorrepairrequiredduetorustor
corrosionarenotcovered.
Thiswarrantyincludesthecostofpartsandlabor,butyoumustpay transportationcosts.
TM
Mowers5yearsor1,200hours*
®
Z400,Z500Mowers
®
G3Mowers5yearsor1,200hours*
2years
2years
Lifetime(originalowneronly)*** 4yearsor1,200hours* 2years** Lifetime(originalowneronly)***
Lifetime(originalowneronly)***
InstructionsforObtainingWarrantyService
IfyouthinkthatyourT oroProductcontainsadefectinmaterialsor workmanship,followthisprocedure:
1.ContactanyAuthorizedT oroServiceDealertoarrangeserviceattheir dealership.Tolocateadealerconvenienttoyou,refertotheYellow Pagesofyourtelephonedirectory(lookunder“LawnMowers”)or accessourwebsiteatwww .T oro.com.Y oumayalsocallthenumbers listedinitem#3tousethe24-hourT oroDealerlocatorsystem.
2.Bringtheproductandyourproofofpurchase(salesreceipt)tothe ServiceDealer .Thedealerwilldiagnosetheproblemanddetermine ifitiscoveredunderwarranty.
3.IfforanyreasonyouaredissatisedwiththeServiceDealer’s analysisorwiththeassistanceprovided,contactusat:
RLCCustomerCareDepartment ToroWarrantyCompany 811 1L yndaleAvenueSouth Bloomington,MN55420-1 196 888-865-5676(U.S.Customers) 888-865-5691(Canadacustomers)
OwnerResponsibilities
YoumustmaintainyourT oroProductbyfollowingthemaintenance proceduresdescribedintheOperator’sManual.Suchroutine maintenance,whetherperformedbyadealerorbyyou,isatyourexpense.
ItemsandConditionsNotCovered
Thereisnootherexpresswarrantyexceptforspecialemission systemandenginewarrantycoverageonsomeproducts. Thisexpresswarrantydoesnotcoverthefollowing:
Costofregularmaintenanceserviceorwearparts,suchaslters,
fuel,lubricants,tune-upparts,bladesharpening,brakeandclutch adjustments.
Anyproductorpartwhichhasbeenalteredormisusedandrequires
replacementorrepairduetonormalwear,accidents,orlackof propermaintenance.
Repairsnecessaryduetoimproperfuel,contaminantsinthefuel
system,orfailuretoproperlypreparethefuelsystempriortoany periodofnon-useoverthreemonths.
Pickupanddeliverycharges.
GeneralConditions
Allrepairscoveredbythesewarrantiesmustbeperformedbyan AuthorizedT oroServiceDealerusingT oroapprovedreplacementparts.
NeitherTheT oroCompanynorT oroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.
Allimpliedwarrantiesofmerchantability(thattheproductistfor ordinaryuse)andtnessforuse(thattheproductistforaparticular purpose)arelimitedtothedurationoftheexpresswarranty
Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,so theaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsoutsidetheUnitedStatesorCanadashouldcontacttheirToroDistributor(Dealer)toobtainguarantee policiesforyourcountry,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguarantee information,contacttheToroimporter .Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany .
374-0252RevA
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